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YAMAHA 






4SU-ME1 



SERVICE 




SZR660('95) 

SERVICE MANUAL 

©1996BELGARDAS.p.A. 

R&D TECHNICAL DIVISION 

V* edition February 1996 

All rights reserved. 

Any reprinting or unauthorised use 

without the written permission ol 

Belgarda S.p.A, is 

expressly prohibited. 



Although some of the drawings and photographs used in this manual are taken from other manuals and do not refer directly to the mode? 
in question, me procedures described and the details illustrated are nonetheless relevant and suitable to the user's purposes. 



WARNING 




HOW TO USE THIS MANUAL 



This manual has been written by Belgarda S.pA mainiy for use by Yamaha dealers and their skilled 
mechanics. It is impossible to provide a mechanic with all the information necessary in a single manual. 
Presumably, though, the people who use this manual for the maintenance and repair of Yamaha motorcycles 
will already have elementary knowledge of the principles of mechanics and the procedures for motorcycle 
repair techniques. Without this knowledge, repair or maintenance work on this model could prove inefficient 
and/or dangerous. 

Yamaha makes constant efforts to improve all its models. Important alterations or changes to procedures 
characteristics will be communicated to all Yamaha dealers and published in future editions of this manual. 
Especially important information in this manual is highlighted by the graphics shown below. 



TECHNICAL PUBLICATIONS 

R&D TECHNICAL DIVISION 

MOTORCYCLE GROUP 

BELGARDA S.p.A. 



PARTICULARLY IMPORTANT INFORMATION 

The manual includes the following symbols and relative remarks: 




A WARNING 



CAUTION: 

NOTE: 



This safety alert symbol means: ATTENTION" BE CAREFUL! YOUR SAFETY IS 
AT RISK! 

The WARNING symbol indicates special procedures to be followed to avoid injury 
to the rider or the person inspecting or repairing the cycle. 

CAUTION indicates special precautions to be taken to avoid damage to the cycle. 

A NOTE provides key information designed to make procedures easier or clearer. 



LAYOUT 

This manual consists of chapters on the principal cycle components (see "Symbol Legend"). 



(1) 
(2) 
(3) 



This symbol, in the top right-hand corner of each page, identifies the chapter graphically. 
This title appears at the top of each page to the left of the chapter symbol, 
The final caption in the chapter "Periodic inspection and adjustment". 



FORMAT 

All the procedures suggested in this manual are arranged in a sequential, step by step order. The information 
is written in such a way as to provide the mechanic with a handy, easy to read reference containing 
explanations on all disassembly, repair, assembly and inspection operations. 

Particularly important procedure sequences (4) are shown between two rows of asterisks (*) and each 
procedure is preceded by the symbol 



"•". 



IMPORTANT SPECIFICATIONS 

• All data and special tools are contained in insets preceded by the specific symbol (5). 

• A number inscribed in round brackets indicates (6) the number of a part, whereas a letter of the alphabet 
indicates alignment data or marks (7); further indications are signalled by a letter eclosed in an inset (8). 

• The condition of a faulty component precedes Qn arrow followed by the procedure required and the symbol 
(9). 

ILLUSTRATED SEQUENCES 

The simplest disassembly and reassembly sequences are shown in an exploded drawing of the parts and 
a table in which the parts themselves are numbered in progressive order of disassembly. Follow the numbers 
progressively to perform the disassembly sequence. Follow the numbered operations in the reverse order 
to perform the reassembly sequence. The table also includes notes to facilitate operations. 

EXPLODED DIAGRAMS 

In some chapters the disassembly section is preceded by exploded diagrams. These are designed to aid 
identification of components for proper assembly, as well as the assembly procedures themselves. 



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SYMBOL LEGEND 

(Refer to illustrations) 

Symbols (1) to (9) are used to indicate chapter 
number and content. 

(1 ) General information 

(2) Technical specifications 

(3) Periodic inspection and adjustment 

(4) Engine overhaul 

(5) Cooling system 

(6) Carburetor 

(7) Chassis 

(8) Electricals 

(9) Troubleshooting 



Symbols (10) to (16) serve to specify the following 
elements: 

(10) Fluid 

(11) Lubricant 

(12) Special tool 

(13) Screw tightening 

(14) Wear and tear limit, clearance 

(15) Engine speed 

(16) Resistance (fi), Voltage (V), Electric Current (A) 



Symbols (17) to (23) in the exploded diagram 
indicate type of lubricant and location of lubrication 
point 

(17) Appfy engine oil 

(18) Apply gear oil 

(19) Apply molybdenum disulfide oil 

(20) Apply wheel bearing grease 

(21) Apply lightweight lithium-soap grease 

(22) Apply molybdenum disulfide grease 

(23) Apply locking liquid (LOCTJTE®) 



CONTENTS 



GENERAL INFORMATION 



TECHNICAL SPECIFICATIONS 



PERIODIC INSPECTION 
AND ADJUSTMENT 



ENGINE OVERHAUL 



COOLING SYSTEM 



CARBURETOR 



CHASSIS 



#^ 



GEN 
INFO 




PI 




B 




INSP 
ADJ 



H 



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ENG 




X 



5 



OOL 



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ARB 




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CHAS 





CHAPTER 1° 
GENERAL INFORMATION 



GEN 
INFO 


I 




GEN 
INFO 


#^ 



IDENTIFICATION OF MOTORCYCLE A-6 

IDENTIFICATION NUMBER A-6 

ENGINE SERIAL NUMBER A-6 

IMPORTANT INFORMATION A-6 

PREPARATION FOR DISASSEMBLY AND REASSEMBLY A-6 

SPARE PARTS A-7 

GASKETS, OIL SEALS AND O-RINGS A-7 

LOCK WASHERS, PLATES AND COTTER PINS A-7 

BEARINGS AND OIL SEALS A-7 

CIRCUPS A-7 

SPECIAL TOOLS A-7 



IDENTIFICATION OF MOTORCYCLE 



GEN 
INFO 


<^N§ 





1. Motorcycle identification number 




1. Engine serial number 



IDENTIFICATION OF MOTORCYCLE 

IDENTIFICATION NUMBER 

The identification number is stamped on the right of 
the steering head pipe. 



Progressive serial number: 

SZR 660 

4SU-040101 (D) version 
ZD04SU10000000101 (l-GR-P) version 
ZD04SU1 00000201 01 
[F-B-N-S-DK-NL-(A-CH)] version 
ZD04SU10000060101 (E) version 



ENGINE SERIAL NUMBER 

The engine seriaf number is stamped on the right of 
the engine- 



Progressive engine serial number: 

SZR 660 

4SU-000101 



NOTE: 



The first three digits in these numbers identify the 
model; the other digits form the progressive 
production number of the unit. 

Diagrams and specifications may be altered 
without prior warning. 



IMPORTANT INFORMATION 



GEN 
INFO 


&% 






IMPORTANT INFORMATION 

PREPARATION FOR DISASSEMBLY AND 

REASSEMBLY 

1 . Remove all dirt, mud, dust and foreign objects 
prior to disassembly. 



2. Use proper material and toots. Refer to sec- 
tion 'SPECIAL TOOLS', 



3. 



When disassembling the cycle, keep together 
mated parts: gears, cylinders, pistons and 
other parts 'mated' in the course of normal 
wear and tear. Such parts must be either re- 
used together or completely replaced. 



4. 



During disassembly, clean all parts and place 
them in trays in order of disassembfy. This 
makes reassembly quicker and helps assure 
that all parts are assembled properly. 




5. Keep away from fire and sources of heat. 



1-1 



1-2 



IMPORTANT INFORMATION 



GEN 
INFO 


<^N§ 



SPARE PARTS 

1. We recommend original Yamaha parts for all 
replacements. Use the oil and grease recom- 
mended by Yamaha for all assembly and 
adjustment operations. 
Products of other makes with the same func- 
tion and appearance might be inferior in 
quality. 

GASKETS, OIL SEALS AND O-RINGS 

1. All gaskets, oil seals and O-rings should be 
replaced during engine overhauls. All gasket 
surfaces, oil seal lips and O-rings must be 
cleaned prior to assembly. 

2. Properly oil all mating parts and bearings 
during reassembly. Apply grease to oil seal 
lips. 




LOCK WASHERS, PLATES AND COTTER PINS 

1 . All lock washers, plates (1 ) and cotter pins 
must be replaced once removed. Lock tabs 
must be bent along the bolt or nut surfaces 

after the bolt or nut has been properly tight- 
ened. 



BEARINGS AND OIL SEALS 

1 . Fit bearings and oil seals with the manufactur- 
er's mark or number facing outwards (ie, the 
stamped letters must be visible). When install- 
ing oil seals, apply a light coating of lightweight 
lithium-based grease to the seal lips. Oil the 
bearings liberally when installing. 



(1) Oil seals 



(£> 
















1 f//J 








I 











CAUTION: 



Do not use compressed air to dry the bearings. 
This damages their outer surface. 

(1) Bearing 




IMPORTANT INFORMATION/ 

SPECIAL TOOLS 




GEN 
INFO 


g!N*5 



CIRCLIPS 

1 . All cirdips should be inspected carefully prior 
to reassembly. Always replace piston ring 
clips after one use. 

Replace twisted cirdips. When installing a 
circlip (1), make sure that the sharp-edged 
corner (2) is positioned opposite the thrust (3) 
it receives. See the illustration here. 



(4) Shaft 



SPECIAL TOOLS 

Special tools are required to perform proper disas- 
sembly and reassembly operations and for proper 
tuning up. The use of such tools avoids damage 
due to the use of unsuitable tools and/or makeshift 
techniques. 

The shape and part number used for the speciaf 
tool differ by country, so two types are provided. 
Refer to the list provided to avoid errors when 
placing an order. 



For USA, CDN 

p/N. YM-nnnnn, 

YS-QDDQD, 
ACC-nODDD 

Except for USA, CDN 

P/N. 90890-aunon 



YU-DDDDa 
YK-OUDDD 



Tool number 


Tool name 


Illustration 


YM-08035 


VALVE ADJUSTMENT TOOL 




90890-01311 


VALVE ADJUSTMENT TOOL 


Cj* ji' 


YU-08036-A 


INDUCTIVE ENGINE 
SPEED INDICATOR 


M 



1-3 



1-4 



SPECIAL TOOLS 



GEN 
INFO 


#^ 



Tool number 



Tool name 






90890-03113 



YM-33277-A 



90890-03141 



YU-33223 



90890-03081 



YU-33223-3 



90890-04082 



YM-01312-A 



90890-01312 



YU-01304 



INDUCTIVE ENGINE 
SPEED INDICATOR 



INDUCTIVE STROBOSCOPE LAMP 



INDUCTIVE STROBOSCOPIC LAMP 



PRESSURE GAUGE 



PRESSURE GAUGE 



ADAPTER FOR PRESSURE GAUGE 



ADAPTER FOR PRESSURE GAUGE 



FUEL LEVEL GAUGE 



Illustration 



FUEL LEVEL GAUGE 



PISTON PIN CLIP PULLER 








9 






O 



n 




^\\ '■ 





SPECIAL TOOLS 



GEN 
INFO 


<?JN5 



Tool number 



90890-01304 



YS-01880 



90890-01 701 



YU-33270 



90890-01362 



YM-04063-A 



90890-04063 



YM-91042 



90890-04086 



YU-01135-A 



Tool name 



PISTON PIN CUP PULLER 



ROTOR HOLDER 



ROTOR HOLDER 



ROTOR SCREW PULLER 



ROTOR SCREW PULLER 



ADAPTER FOR ROTOR SCREW 
PULLER 



ADAPTER FOR ROTOR SCREW 
PULLER 



ALL-PURPOSE CLUTCH HOLDER 



ALL-PURPOSE CLUTCH HOLDER 



CRANKCASE SEPARATING TOOL 



Illustration 





.-^ 



© 



a 






^ 



X 





f^a 









1-5 



1-6 



SPECIAL TOOLS 



GEN 
INFO 


#^ 



Tool number 



90890-01135 



YU-01083-A 



90890-01083 



90890-01084 



YM-04019 



90890-04019 



YM-91043 



YM-04064 



90890-04064 



YM-04066 



Tool name 



CRANKCASE SEPARATING TOOL 



SLIDING HAMMER UNIT 



SLIDING HAMMER BOLT 



Illustration 



SLIDING HAMMER WEIGHT 



VALVE SPRING COMPRESSION 
CLAMP 



VALVE SPRING COMPRESSION 
CLAMP 



VALVE HOUSJNG CUTTER 



6 mm (0.24 in) VALVE GUIDE PULLER 



6 mm (0.24 in) VALVE GUIDE PULLER 



6 mm (0.24 in) VALVE GUIDE REAMER 



IV 



ri 



j On? 













SPECIAL TOOLS 



GEN 
INFO 


$^5 



Tool number 



90890-04066 



YM-04065-A 



90890-04065 



YU-90050 



90890-01274 



90890-01275 



YM-90069 



90890-04059 



YM-91044 



90890-04081 



Tool name 



6 mm (0-24 in) VALVE GUIDE REAMER 



6 mm (0.24 in) VALVE GUfDE 
INSTALLER 



6 mm (0.24 in) VALVE GUIDE 
INSTALLER 



DRIVING SHAFT 
INSTALLATION UNIT 



DRIVING SHAFT 

INSTALLATION HOSE 



DRIVING SHAFT 

INSTALLATION BOLT 



#10 (M14) ADAPTER 
(FOR DRIVING 
SHAFT INSTALLATION) 



#10 (M14) ADAPTER 
(FOR DRIVING 

SHAFT INSTALLATION) 



CRANK SPACER 



CRANK SPACER 



Illustration 







© 








1-7 



1-8 



SPECIAL TOOLS 





Tool number 



90890-01288 



Tool name 



SPACER (FOR CRANK) 



ACC-11001-01 



90890-85505 



YU-24460-01 



90890-01325 



YU-33984 



SEALANT (QUICK GASKET)' 
Yamaha Bond No. 1216® 



SEALANT (QUICK GASKET)® 
Yamaha Bond No- 1215® 



Illustration 



RADIATOR CAP TESTER 



RADIATOR CAP TESTER 



ADAPTER 

(FOR RADIATOR CAP TESTER) 



90890-01352 



ADAPTER 

(FOR RADIATOR CAP TESTER) 



4SU-F8120-W0 



YU-01268 



90890-01268 



FRONT FORK SERVICE KIT ASSY 



RING NUT WRENCH 



RING NUT WRENCH 













Tool number 



90890-01385 



YM-34487 



90890-03144 



YU-031 1 2 



90890-03112 



Tool name 



RING NUT WRENCH 



D1NAM1C SPARK TESTER 



IGNITION CHECKER 



POCKET TESTER 



POCKET TESTER 



SPECIAL TOOLS 



GEN 
INFO 


<^^5 



Illustration 










1-9 



1-10 



spec 0/ 



CHAPTER 2° 
TECHNICAL SPECIFICATIONS 




SPEC 


f>t 



GENERAL SPECIFICATIONS A-13 

MAINTENANCE SPECIFICATIONS A-14 

ENGINE A-14 

ELECTRIC SYSTEM A-16 

CHASSIS B-2 

TIGHTENING TORQUES B-3 

GENERAL TORQUE SPECIFICATIONS B-6 

DEFINITION OF MEASUREMENT UNITS B-6 

LUBRICATION POINTS AND TYPE OF LUBRICANT B-7 

ENGINE B-7 

CHASSIS B-7 

LUBRICATION LAYOUT B-8 

COOLING LAYOUT B-10 

CABLE ROUTING 8-11 



GENERAL SPECIFICATIONS 



SPEC 09 




GENERAL SPECIFICATIONS 



SPEC pf 



TECHNICAL SPECIFICATIONS - GENERAL SPECIFICATIONS 



Model code number 

Initial engine stamp number 

Initial frame stamp number 


4SU1 

4SU-000101 

4SU-040101 (D) version 

2D04SU 10000000101 (l-GR-P) version 
ZD04SU10000020101 (F-B-N-S-DK-NL-(A-CH)] 

version 
ZD04SU1 00000601 01 (E) version 


Dimensions: 
Overall length 
Overall width 
Overall height 
Seat height 
Wheel base 
Minimum ground clearance 


2,040 mm 
740 mm 
1.140 mm 
770 mm 
1,410 mm 
145 mm 


Basic weight 


159 kg 


Minimum turning radius 


3,150 mm (left); 3,200 mm (right) 


Engine: 
Engine type 
Model 

Cylinder layout 
Displacement 
Bore x stroke 
Compression ratio 
Starting system 


4-sUoke, SOHC, liquid cooled, 5-vafve 

4SU1 

Single cylinder, inclined forward 

659 cc 

100x84 mm 

9.2:1 

Electric starter 


Lubrication: 

Type 

Recommended engine oil 


Dry sump with separate oif tank 
SHELL SUPER 4TX 20W/50 


Capacity (engine oil): 

Periodic oil change 

With oil filter replacement 

Total amount 


2.6 liters 

2.7 liters 

3.0 liters 


Cooling system: 
Type 

Water/cooiing liquid ratio 
Circuit liquid total quantity 

Expansion tank capacity 
From "LOW to "FULL" 


Liquid with forced circulation and electric fan 
50% - 50% 

1.4 liters 

0.55 (iters 
0.210 liters 


Air filter: 
Type 


Dry filter element 

_ i i 


Fuel (type): 

Tank capacity: 
Total 
Reserve amount 


Premium Grade Fuel. If Premium Grade gasoline 
is not available, then unleaded gasoline with 
octane grade (R.O-N.) of 91 or higher can be used 

14 liters 
2.5 liters 


Carburetor; 

Type/Manufacturer 


Y26PV-3J/TEIKEI 


Spark plug: 
Type/Manufacturer 
Electrode gap 


DPR8EA-9 or DPR9EA-9/NGK 
0-8^0.9 mm 


Clutch: 
Type 


Wet, multi-disc 



Transmission: 




Type 


Constant mesh 5-speed 


Primary reduction system 


Straight-tooth gears 


Primary reduction ratio 


71/34(2-088) 


Secondary reduction system 


Chain drive 


Secondary reduction ratio 


39/15(2.600) 


Operation 


Left foot operation 


Gearratio: 1st 


30/13(2.308) 


2nd 


27/17(1.588) 


3rd 


24/20(1.200) 


4th 


21/22 (0.954) 


5th 


19/24(0.792) 


Frame: 




Frame type 


Deitabox aluminium frame 


Caster angle/Trail 


24°/102mm 


Tires: 




Type 


Tubeless 


Size: 




Front 


1 10/70 2R17 TX15 (MICHELIN) - 




1 10/70 ZR17TL(DUNLOP) 


Rear 


150/60 ZR17 TX25 (MICHELIN) - 




150/60 ZR17 TL (DUNLOP) 


Tire inflation pressure (cold tires) bar-kg/cm ? (psi) 
Rider only 

With passenger 


Front 


Rear 


2 (28) 


2.2 (32) 


2-2 (32) 


2.5 (37) 


Brakes: 




Front brake type 


Single 320 mm disk brake 


Operation 


Right hand operation 


Rear brake type 


Single 210 mm disk brake 


Operation 


Right foot operation 


Front suspension: 


Adjustable upside-down telescopic fork, 




dia. 41 mm, Upside Down 


Rear suspension; 


Aluminium swinging fork with 




adjustable shock absorber 


Wheel travel: 




Front 


120 mm 


Rear 


121.5 mm 


Electric system: 




Ignition system 


T.C.I. (Digital) 


Battery type/Voftage 


CTX9 BS YACHT MF/12V 8Ah 


Fuses 


20A (Main) * 7.5A (Electric fan) 


Generator 


A.C. 12V 


Headlight type 


Provided with quartz lamp (halogen) 


Bulb specifications; 




Headlights (halogen) 


12V-2x55W 


Tai^Brake light 


12V-21/5W 


Turn lights 


12V-10W 


Front parking light 


12V-5W 


Numberplate light 


1 2V-5W 


Warning famps: "NT (neutral) - "High beam" 


12V-4x1.2W 


"Low fuel" - "Turn lights* 





2-1 



2-2 



MAINTENANCE SPECIFICATIONS 



SPEC 09 




MAINTENANCE SPECIFICATIONS 



ENGINE 



Part 



Standard 



Cylinder head: 




Cylinder: 
Sore 

Measurement point (a) 




Cam shaft: 

Advance method 

Cam shaft outer diameter 

Backlash between cam shaft and cap 

Cam size: 



Suction: "A" 

"C" 

Exhaust: "A" 

"B* 
"C" 




Cam shaft eccentricity limit 



Timing chain: 
Timing chain type 
Link number 
Timing chain adjustment 
method 



100.005- 1 00.07 mm 
50 mm 



Chain advance (left) 

22.967 ~ 22,980 mm 
0.020 - 0.054 mm 



35.69 - 35.79 mm 
30.06 - 30-16 mm 
5.74 mm 

36.50 - 36.60 mm 
30.11 -30.21 mm 
6.55 mm 



75 RN 2015 
126 links 

Automatic 



Rocker/rocker shaft: 
Rocker outer diameter 
Rocker shaft inner diameter 
Rocker-shaft backlash 



12.000- 12.018 mm 
11.976- 11.991 mm 

0.009 ~ 0.042 mm 



Limit 



003 mm 

The lines show where 
you have to site the 
measuring slide rule 



100.1 mm 



35.54 mm 
29.91 mm 

36.35 mm 
29.96 mm 



0.03 mm 



MAINTENANCE SPECIFICATIONS 




Part 



Standard 



Valves, valve seats, 
valve guide: 
Valve clearance (cold): 
Suction 
Exhaust 



Valve sizes: 
Suction: 

"A a head diameter 

"B" face width 
M C" seat width 
M D M edge thickness 

Exhaust: 
"A" head diameter 

"B" face width 

"G" seat width 

- D - edge thickness 



0,10- 0.15 mm 
0.15- 0.20 mm 



29.9 - 30.1 mm 

2.25 mm 

0.9- 1.1 mm 
0.85 ~ 1.15 mm 

31.9-32.1 mm 

2.26 mm 

0.9 - 1.1 mm 
0-85 - 1.15 mm 



Limit 



£3 

Head 

diameter 





"C" 



i 



(zi'*D 



ri 



Face 
width 



Seat 
width 



Edge 
thickness 



Rod outer diameter: 
Suction 

Exhaust 

Guide inner diameter: 
Suction 

Exhaust 

Backlash between rod and guide: 
Suction 

Exhaust 

Rod eccentricity limit 




Valve seat standard width: 
Suction and Exhaust 



5,975 - 5-990 mm 
5.960 - 5.975 mm 

6.000 mm ~ 6.012 mm 
6.000- 6.012 mm 

0.010 mm -0.037 mm 
0,025 - 0.052 mm 



0,9- 1.1 mm 



5.95 mm 

5.93 mm 

6.05 mm 

6.55 mm 

008 mm 
0.1 mm 

0.01 mm 



2-3 



2-4 



MAINTENANCE SPECIFICATIONS 



Part 



Valve springs: 
Free length: 

Suction 

Exhaust 
Position size 
(with closed valve): 

Suction 

Exhaust 
Winding sense (top view): 

Suction and exhaust 

Slope limit: 



Suction 

Exhaust 




V\W 



Compression force (with closed valve): 
Suction 
Exhaust 



Piston: 

"D" piston size 
"H" measurement 
point 









< 


y 


— D~ 


J 



Piston allowance 

Piston pin off-centring 

Piston-cylinder backlash 



H 



Standard 



32.63 mm 
36.46 mm 



27.50 mm 
31-00 mm 

Clockwise 




10.2-11.8 kg 
12.3-14.1 kg 



99.945 - 99.985 mm 
2.5 mm 



1.0 mm 

Suction side 
0-050 - 0.070 mm 



Limit 



2-571 .4 mm 

2.571.6 mm 



0.15 mm 



Rings: 
Type: 
Upper ring 
Lower ring 

Sizes (BxT): 
Upper ring 

Lower ring 

Scraper ring 



J3 


\ i 


ii= i 



a 



B 



B 



L-T— 



Trapezoidal 
Conic 



B= 1.2 mm 
T s= 3.8 mm 

B = 1 .2 mm 

T = 4.0mm 

8 = 2.5 mm 

T = 3.4 mm 



2-5 



MAINTENANCE SPECIFICATIONS 




Part 


Standard 


Limit 


End clearance (with mounted ring): 
Upper ring 

Lower ring 

Scraper ring 

Side backlash (with installed ring): 
Upper ring 

Lower ring 

Scraper ring 


0.30 ~ 0.45 mm 
0.30 - 0.45 mm 
0.20 - 0.70 mm 

0.04 - 0.08 mm 
0.03 ~ 0.07 mm 
0.015-0.042 mm 


— 


Main shaft: 

"A" shaft width JT 
*C* off-centring © nln 
limit t_o |1 
*D h backlash *£^ 1 

T" small end -JJ 

backlash K " 


1 


74.95 - 75.00 mm 

0.35 ~ 0.65 mm 
0.8 - 1 .0 mm 


0.03 mm 


Balancing weight; 
Advance method 


Cylinder gear 




Ciutch: 
Friction plate: 

Thickness 
Quantity 

Friction plate; 
Thickness 
Quantity 

Clutch plate: 
Thickness 

Quantity 
Distortion limit 

Clutch spring: 
Free length 
Quantity 

Clutch release method 


2.74 ~ 2.86 mm 

6 parts 

2.94 ~ 3.06 mm 
2 parts 

1.2 mm 

7 parts 

42.8 mm 

5 parts 

Rack and pinion external 
traction 


2.6 mm 
2.8 mm 

0.2 mm 
40.8 mm 


Gear box: 

Principal axis off-centring 

limit 

Intermediate shaft off-centring 

limit 


— 


0.08 mm 
0.08 mm 


Selector: 
Type 


Drum with cam 

and guide bar 





2-6 



MAINTENANCE SPECIFICATIONS 




Pari 


Standard 


Limit 


Lubrication system; 








Oil filter: 








Type 




Paper 




Oil pump: 








Type 




Trochoidal 




Extremity clearance 




0.12 mm 


— 


Lateral clearance 




0.03 - 0.08 mm 


— 


Derivation valve adjustment pressure 


80-120 kPa (0.8 ~ 1.2 kg/cm 2 ) 


— 


Cooling system: 








Radiator 


Width 


431 mm 


— 




Height 


133 mm 


— 




Thickness 


32 mm 


— 


Valve adjustment pressure 




95 - 125 kPa (0.95 - 1.25 kg/cm 2 ) 


— 


Expansion tank capacity 




0,55 litri 


— 


From "LOW" to "FULL" 




0.210 iitri 


— 


Liquid pump: 








Type 




Single suction centrifugal pump 




Reduction ratio 




33/34(0.971) 


— 


Thermostat; 








Opening temperature 




80~84°C(176- 183 V F) 


— 


Carburetor: 








Identification initials 




4SU-00 


— 


Main jet 


(MJO 






Primary carburetor 




#140 


— 


Secondary carburetor 




#165 


— 


Main air jet 


(M.A.J.) 






Primary carburetor 




01.0 


— 


Secondary carburetor 




01.0 


— 


Jet needle 


(J.N.) 






Primary carburetor 




5D96-3/5 


— 


Secondary carburetor 




5X7C-4/5 


— 


Nozzle jet 


(NJ.) 






Primary carburetor 




V-00 


— 


Secondary carburetor 




02.7 


— 


Pilot air jet 


(P.A.JO 


0.6 


— 


Pilot jet 


(P.J.) 


#50 


— 


Pilot output 


(P.O.) 


0,8 


— 


By pass 


<B.P.) 


01.0 


— 


Pilot screw 


(P.S.) 


ca. 3 turns open 


— 


Valve seat 


(V.S.) 


2.5 


— 


Starter jet 


(G.S.) 


#76 


— 


Fuel level 


(F.L) 


6.0-8.0 mm under float chamber 
matching surface 


^" 


Float height 


(F-H.) 


25.0-27.0 mm 


— 


Engine idle speed 




1,300 + 50 rpm - 




Suction pressure at engine 


idie speed 


26.6-34.6 kPa {200-260 mmHg) 





MAINTENANCE SPECIFICATIONS 



SPEC 09 



ELECTRIC SYSTEM 



Part 



Voltage: 



Standard 



12V 



Limit 



Ignition system: 

Minimum spark advance {B.T.D.C.) 
Maximum spark advance (B.T.D.C.) 
Spark advance device 



50 -i 



1 2° at 1 1 300 rpm 
38° at 6,500 rpm 

Electric type 






12.9°/700rpm 



o 

c 

> 



cd 

ex 



40 ■ 



30 - 



20 - 



10 • = 




i 



X38°/6,50Q rpm 



24°/3 t 000+20Q rpm 



14°/2,555±200 rpm 



1 



2 3 4 5 6 7 8 

Engine speed (x 1,000 rpm) 



-i r~ 

9 10 



Spark unit: 

Model/Manufacturer 

Pick-up coil resistance 
(colour) 



Ignition coil: 
Model/Manufacturer 

Primary coil resistance 

Secondary coil resistance 



TMDF19/NIPPONDENSO 

184-276 at 20°C (68°F) 
(Biue/Yelfow - Green/White) 



J0268/NIPPONDENSO 
3.4-4.6 Q at 20°C (68°F) 
10.4-15.6 kQ at 20°C {68°F) 



Spark plug cap: 
Type 
Spark plug cap resistance 



Charge system: 
Type 



Resin 
10ktlat20°C(68F) 



CA magnet generator 



2-7 



2-8 



MAINTENANCE SPECIFICATIONS 





Pari 



AC Alternator: 
Model/Manufacturer 

Recharge output 
Armature resistance {winding) 
(colour) 



Standard 



TLMZ55/N1PPONDENSO 
14V,24.5A at 5,000 rpm 
0.20-0.30 Q at 20°C (68°F) 

(White - White) 



3 

a 

o 

a> 

o 

a: 



26 

24 

22 

20 

IS 

16 

14 

12 

10 

8 

6 

4 
2 












1 


Ml! 








| 






_L 










_LLLi 






















































_-_-. 


















i 




















[ 










_, 








■- 




ill 


— 






















— 


— 








-.-. 






















































frm 






















— 


— 


/- 








_.. 




--. 




































— ♦ 

















" 


Li 
















4- 










r 














Tl 










"l~l 











Limit 



Battery: 
Electrolyte density 



Electric smarter system: 
Type 

Starter motor: 

Model/Manufacturer 

Capacity 

Brush length 

Commutator diameter 

Mica cut (depth) 
Ignition relay: 

Model/Manufacturer 

Nominal amperage 

Horn: 

Type 

Model/Manufacturer 
Max, intensity 



o 1 



8 



Engine speed { x 1 ,000 rpm) 



Voltage regulator/Rectifier: 

Model/Manufacturer 

Voltage regulator: 

Type 

Not charged adjusted voltage 
Rectifier: 

Capacity 

Resistance voltage 



SH650A/SHINDENGEN 

Short circuit semiconductor 
14.2-15.2V 

25A 

240V 



1.320 



Constant mesh gear 

SM-13/MITSU8A 
0.8 kW 
12.5 mm 
28 mm 
0.7 mm 

MS5D-191/HITACHI 

100A 



Flat 

220/CEV-PAGAN! 

2.5A 



5 mm 
27 mm 



MAINTENANCE SPECIFICATIONS 



SPEC 0Y 



Pari 


Standard 


Limit 


Turn light relay: 
Type 

Model/Manufacturer 
Automatic stop device 
Flashing frequency 
Power 


Warm-wire type 

301877102/CEV-PAGANI 

None 

60-120 cycles/min 

10Wx2+2W 


— 


Electric fan: 

Model/Manufacturer 


VA27-A37/C-46A 12V/SPAL 




Thermostatic switch: 
Model/Manufacturer 
Operating temperature 


VF105A/N. THERMOSTAT 
102~108°C <215.6~226.4°C): ON 
98°C (208.4°F): OFF 


— 


Thermo unit: 
Model/Manufacturer 
Coil resistance 


KIAL 41/NIPPONDENSO 
226 £2 at 50°C(122°F) 
26.4 Q at 11 5°C 


— 


Electric circuit switch device: 
Type 

Individual amperage 


Fuse 

20A (main) 
7.5A (electric fan} 





2-9 



2-10 



MAINTENANCE SPECIFICATIONS 



spec pf 




MAINTENANCE SPECIFICATIONS 



SPEC 9f 



CHASSIS 



Part 


Standard 


Limit 


Steering: 
Bearing type 


Taper roller bearing 




Front suspension: 
Fork travel 

Fork spring: free length 
Spring constant (K) 
Optional spring 
Oil amount 
Oil level 

Oil type: 

Inner tube external diameter 


120 mm 
402 mm 
7.95 N/mm (0.795 kg/mm) 

None 
300 cu.cm 

130 mm 

from upper edge 

of inner tube {fully 

compressed, without spring) 
BELRAYMC10SAE5 
41 mm 




Rear suspension: 
Shock absorber travel 
Free spring length 
Spring-loaded length: 

Standard 

Minimum 

Maximum 
Spring constant (K) 
Travel 

Optional spring 
Gas pressure 


48 mm 
175 mm 

166 mm 
161 mm 
170 mm 
125 N/mm (12.5 kg/mm) 

Zero-65 mm 
None 

12kg/sqcm(170psi) 


■^™ 1 


Rear arm: 
Clearance limit 

Side clearance 


0.4-0.7 mm 

at the rear arm axle 


1 .0 mm at the rear 
arm end (move rear 
arm from side to side) 


Front wheel: 
Type 
Rim size 
Wheel material 
Wheel eccentricity limit: 

Vertical 

Lateral 


Light alloy 

3.00x17" 

Aluminium 


0.5 mm 
0.5 mm 



Part 


Standard 


Limit 


Rear wheel: 








Type 


Light alloy 






Rim size 


4.00x17" 






Wheel material 


Aluminium 






Wheel eccentricity limit 








Vertical 


— 


0-5 mm 




Lateral 


— 


0-5 mm 




Drive chain: 








Type/Manufacturer 


135 ORS-A REGINA CHAIN 






Number of finks 


110 






Chain slack 


25-40 mm 


— 




Front disk brake: 








Type 


Single 






External disk diameter 


320 mm 






Disk thickness 


4 mm 


3.5 mm 




Pad thickness 


5.0 mm 


0-8 mm 




Internal master cylinder diameter 


13 mm 






Interna! caliper cylinder diameter 


30/34 mm 






Quantity 


2 parts 






Brake fluid type 


DOT #4 






Rear disk brake: 








Type 


Singfe 






External disk diameter 


210 mm 






Disk thickness 


5 mm 


4 mm 




Pad thickness 


4.0 mm 


0.8 mm 




Internal master cylinder diameter 


11 mm 






Internal caliper cylinder diameter 


32 mm 






Brake fluid type 


DOT #4 






Brake pedal lever: 








Brake lever free play (travel) 


2-5 mm 

at the lever end 


•** 




Brake pedal position 


50 mm 

below the footrest 

plane 






Clutch lever and throttle grip: 








Clutch lever free play 


10-15 mm 
at the lever end 


^~ 




Throttle cable free play 


3.0-5.0 mm 

at the grip flange 







2*11 



2-12 



MAINTENANCE SPECIFICATIONS 



TIGHTENING TORQUES 



SPEC 09 




MAINTENANCE SPECIFICATIONS 




Part to be tightened 


Thread 
size 


Q.ty 


Tightening torque 


Note 


Nm mkg 


Head 












Flange bolt 


M9 


4 


38 


3.8 




Flange bolt 


M9 


2 


38 


3.8 




Socket head bolt 


M6 


1 


10 


1.0 




Stud bolt (exhaust pipe) 


M6 


4 


7 


0.7 




Screw plug 


M18 


— 


55 


5.5 


,0 


Spark plug 


M12 


1 


18 


1.8 


Cylinder head cover 












Socket head bolt 


M6 


16 


10 


1.0 




Cylinder head cover 












Socket head bolt 


W6 


1 


10 


1.0 




Cylinder head lateral cover 


M32 


2 


12 


1.2 




Socket head bolt 


M6 


4 


10 


1.0 




Gear unit assembling 












Socket head bolt 


M€ 


1 


10 


1.0 




Engine speed indicator stop cap 












Flat head screw 


M6 


1 


7 


0.7 




Cylinder 












Flange bolt 


M10 


2 


42 


4.2 




Flange bolt 


M10 


2 


42 


4.2 




Socket head bolt 


M6 


2 


10 


1.0 




1 Support 












Socket head bolt 


M6 


1 


10 


1.0 




Balancer shaft gear 












Hexagonal nut 


M16 


1 


60 


6.0 


Use a 


Rotor (AC magnet) 










lock 


Hexagonal nut 


M14 


1 


150 


15.0 


washer 


Lock nut (valve clearance adjustment) 












Hexagonal nut 


M6 


4 


14 


1.4 




2 retainer guide 












Hexagonal bolt 


M6 


2 


8 


0.8 




Timing sprocket 












Flange bolt 


M7 


2 


20 


2.0 




Timing chain tensioner 












Hexagonal head bolt 


M6 


2 


10 


1.0 




Rocker shaft stop 












Socket head bolt 


M6 : 


2 


10 


1.0 




Cooling liquid pump 












Socket head bolt 


M6 


3 


10 


1.0 




1 tube 












Socket head bolt 


M6 


1 


10 


1.0 




2 tube 












Flange bolt 


M6 


1 


10 


1.0 




Thermostat assembly 












Flange bolt 


M6 


2 


10 


1.0 






Part to be tightened 


Thread 


Q.ty 


Tightening torque 


Note 








size 




Nm 


mkg 




Filler (coolant) 












Cylindrical socked head bolt 


M6 


1 


10 


1.0 




Oil pump 












Socket head bolt 


M6 


2 


10 


1.0 




Oil delivery/return hose 












Truncated cone head screw 


M6 


2 


7 


0.7 




Draining plug (oil sump) 


M14 


1 


30 


30 




Oil filter cover 












Socket head bolt 


M6 


3 


10 


1.0 




Drainage screw 


M5 


1 


5 


0.5 




Radiator 












Flange boit 


M6 


4 


10 


1.0 




Oil pump assembly 












Flange bolt 


M6 


3 


10 


1.0 




2 cover 












Truncated cone head screw 


M6 


1 


7 


0.7 




Oil suction net filter 












Truncated cone head screw 


M6 


2 


7 


0.7 




Drainage hote 












Plug screw 


M14 


1 


30 


3.0 




Filter cover 












Socket head bolt 


M6 


1 


10 


1.0 




Socket head bolt 


M6 


2 


10 


1.0 




Fitter cover drainage 












Screw 


M5 


1 


5 


0.5 




1 oil tube 












Socket head bolt 


M6 


4 


10 


1.0 




Drilled joint 


M12 


1 


35 


3.5 




2 oil tube 












Socket head bolt 


M6 


2 


10 


1.0 




Drilled joint 


M12 


1 


35 


3.5 




Connecting oil hose 












Bolt 


M10 


2 


20 


20 




Socket head bolt 


M6 


1 


10 


1.0 




Carburetor joint 












Socket head bolt 


M6 


4 


10 


1.0 




Left carburetor joint 












Clamp 


M4 


1 


2 


0.2 




Right carburetor joint 












Clamp 


M5 


1 


5 


0.5 




Carburetor joint (left, air filter) 












Clamp 


M4 


1 


2 


0.2 




Carburetor joint (right, air filter) 












Clamp 


W5 


1 


5 


0.5 





2-13 



2-14 



MAINTENANCE SPECIFICATIONS 



SPEC 09 




MAINTENANCE SPECIFICATIONS 



spec p9 



Part to be tightened 


Thread 


Q.ty 


Tightening torque 


Note 


4 






^r 


size 




Nm 


mkg 




Air cleaner case 












SeJf-tapping screw 


M9 


7 


5 


0.5 




Air cleaner cover 












Crosshead screw 


M5 


3 


5 


0.5 




Exhaust pipe 












Nut 


M6 


4 


10 


1.0 




1*2 exhaust pipes 












Socket head bolt 


M6 


1 


10 


1.0 




Silent-Block to frame 












Range nut 


M8 


1 


23 


2.3 




Silent-Block to bracket 












Flange nut 


M8 


1 


23 


2.3 




1 exhaust pipe to bracket 












Flange screw 


M8 


1 


23 


2.3 




Muffler and exhaust pipe 












Socket head bolt 


M6 


1 


10 


1.0 




Muffler assembling 












Flange bolt 


M10 


1 


40 


4.0 




1 - 2 oil sump 












Socket head bolt 


M6 


9 


10 


1.0 




Socket head bolt 


M6 


4 


10 


1.0 




Socket head bolt 


M6 


1 


10 


1.0 | 




Holdfast (cable) 












Truncated cone head screw 


M6 


1 


7 


0.7 




1 crankcase cover 












Socket head bolt 


M6 


6 


10 


1.0 i 




Socket head bolt 


M6 


1 


10 


1.0 I 




Socket head bolt 


M6 


1 


10 


1.0 




Socket head bolt 


M6 


1 


10 


1.0 




Plug screw 


M8 


1 


10 


1.0 | 




2 crankcase cover 












Socket head bolt 


M6 ' 


2 


10 


1.0 




3 crankcase cover 












Socket head bolt 


M6 


5 


10 


1.0 




Socket head bolt 


M6 


3 


10 


1.0 




Socket head bolt 


M6 


2 


10 


1.0 




Bearing cover plate 












Flat head screw 


M6 


3 


7 


0.7 


-*3 


Locking plate 










Socket head bolt 


M6 


2 


10 


1.0 




Clutch spring 












Screw with washer 


M6 


5 


8 


0.8 




Clutch hub 












Nut 


M20 


1 


90 


9.0 


Use a 
lock 


Primary transmission gear 










washer 


Nut 


M20 


1 


120 


12.0 , 


Use a 
lock 


Thrust lever assembly (stop) 










washer 


Bolt 


M6 


1 


6.5 


0.65 




Thrust lever assembly 












Screw 


M8 


1 


12 


1.2 







Thrpari 




Tightening torque 




Part to be tightened 


• • It ^Q\J 


Q.ty 




Note 








size 




Nm 


mkg 




Guide sprocket 










Use a 


Nut 


M18 


1 


110 


11.0 


lock 


Oil seal cover 










washer 


Socket head bolt 


M6 


2 


10 


1.0 




Stop lever 












Screw with washer 


M6 


1 


10 


1.0 




Gearbox arm 












Bolt 


M6 


1 


10 


1,0 




Stator coil 












Truncated cone head screw 


M6 


3 


7 


0.7 


o 


Neutral switch 


M10 


1 


20 


2.0 


1 lateral cylinder head cover 


M32 


2 


12 


1.2 




Spring tensioner 












Hole 


M16 


1 


20 


2.0 




Starter 












Flange bolt 


M6 


2 


10 


1.0 




1 cover 












Socket head bolt 


M6 


1 


10 


1.0 




Socket head bolt 


M6 


3 


10 


1.0 




Starter unidirectional clutch 










Stop -i{3 


Socket head bolt 


we 


3 


30 


3.0 


Pick-up coif 










-0 


Truncated cone head screw 


M5 


2 


5 


0.5 


Ignition coil 












Socket head bolt 


M5 


2 


5 


0,5 




Voltage regulator 












Hexagonal head bolt 


M6 


2 


5 


0.5 




Ignition unit 












Hexagonal head screw 


M6 


2 


5 


0.5 




Thermo switch 












Truncated cone head screw 


M16 


1 


28 


2.8 




Thermo unit 












Truncated cone head screw 


PT1/8 


1 


15 


1.5 





2-15 



2-16 





FICAT 






| B-5 




NTENANCE SPECIFICAT 










IONS 


SPEc\fif 


IONS 


SPEC 


Pf 


MAINTENANCE SPECI1 






MAI 




Part to be tightened 


Thread 
size 


Q.ty 


Tightening 
torque 


Note 




Part to be tightened 


Thread 
size 


Q.ty 


Tightening 
torque 


Note 


Nm 


mkg 






Nm 


mkg 


Engine assembling: 
Front engine bracket and frame 
Front engine bracket and engine 

Upper cylinder head bracket and frame 

Upper engine bracket and cylinder head 

Rear/upper engine and frame 

Rear/lower engine and frame 
Lower/rear engine axle tightening 

Driver footrest and frame 


M10x 1.25 
MtOx 1.25 

M10x 1.25 

M10x 1.25 

M10X1,25 

MIOxl.25 

M6 x1.0 

M8 x 1.25 


1 
2 

2 

1 

1 

1 
1 

4 


65 
65 

65 

65 

65 

65 
10 

23 


6.5 
6.5 

6.5 

6.5 

6.5 

6.5 
1.0 

2.3 


Axle 

Flange bolt and 

locknut 

Socket head bolt 

and locknut 

Socket head bolt 

and locknut 

Socket head bolt 

and locknut 

Bolt 

Socket 

head screw 

Special screw 


Passenger footrest and frame 
Footrest to bracket 

Side stand: 

Side stand bracket to frame 

Stand pivot 

Stand nut 
Rear small frame: 

Upper rear small frame to main frame 
fastening 

Lower rear small frame to main frame 
fastening 
Front small frame: 

Rear small frame to steering head fastening 

Rear sma!l frame to main frame 
fastening 
Side panel/fender/rear cowling/fuel tank; 
Rear wheel fender to rear arm 
Front wheel fender to front fork 
Front wheel fender to front fork 

Battery case to rear smalJ frame 
Rear cowling to rear small frame 
Fuel tank to frame 

Fuel tank to rear small frame 
Fuel pump to bracket 
Bracket to fuel tank 
Front small frame and headlight 
Front small frame and instrumentation 
Front small frame and mirrors 
Side panel to frame bracket 
Bracket to frame 

Air connection to front small frame 
Side panel, air connection to bracket 
Front fork/handle bar: 
Handle crown and fork 
Handle crown and handle bar fastening 


M8 xl.25 

M10x 1.5 

M10x 1.25 
M10X1.25 
M10x1.25 

M10x 1.25 

M8 X1.25 

M8 xl.25 
M8 x 1 .25 

M6 x 1 
M6 xl 
M6 x 1 

M6 x 1 
M6 x1 
M6 xl 

M6 x1 
M5 xO.75 
M6 xl 
M6 xl 
M5 xO.75 
M6 xl 
M6 X1 
W6 x 1 
M6 x1 
M5 XO.75 

M8 xl.25 
M6 x1 


4 
2 

2 
1 
1 

2 

2 

2 
1 

3 

4 
2 

5 
2 

1 

1 

2 

2 
4 

3 
4 
2 

2 

2 

3 

2 
2 


25 
50 

55 
40 
35 

40 

23 

25 
23 

10 
10 
10 

10 
10 
10 

10 

5 

7 

7 

5 

10 

10 

10 

10 

5 

23 

10 


2.5 
5.0 

5.5 

4.0 
3.5 

4.0 

2.3 

2.5 
2.3 

1.0 
1.0 
1.0 

1.0 
1.0 
1.0 

1.0 
0.5 
0.7 
0.7 
0.5 
1.0 
1.0 
1.0 
1.0 
0.5 

2.3 

1.0 


Hexagonal head screw 
with flange 
Socket thin head 
screw 

Screw 
Pivot 

Special nut 

Hexagonal head screw 

with flange 

Hexagonal head screw 
with flange 

Hexagonal head screw 
with flange 

Hexagonal head screw 
with flange 

Hexagonal head screw 
Socket thin head screw 
Socket thin head screw 

and locknut 
Hexagonal head screw 
Socket thin head screw 
Large socket thin head 
screw 

Socket thin head screw 
Flange nut 

Cylindrical head screw 
Locknut 
Flange nut 
Flange cap nut 
Hexagonal head screw 
Socket thin head screw 
Socket head screw 
Socket thin head screw 


Tightening sequence; 
Crankcase (L) 






Crankcase (R) 

\Qry[ \ / 

/ h %© 

s^ J Jao) 

-19 




® (5flt 


JH^'p- 




/T\ 3=T /k\ 




W @ W 






















Socket head screw 
Socket head screw 


t 
r 



2-17 



2-18 



MAINTENANCE SPECIFICATIONS 




B-6 





Thread 
size 




Tightening 




Part to be tightened 


Q.ty 


torque 


Note 


Nm 


mkg 


Under bracket and fork 


M8 X1.25 


4 


23 


2.3 


Socket head screw 


Handle bar fastening to fork 


M8 xl 25 


4 


23 


2.3 


Socket head screw 


Handle crown nut 


M22 x 1 .0 


1 


110 


11.0 


Nut 


Counterweight to handle bar fastening 


M8 x 1 .25 


2 


25 


2.5 


Socket head screw 


Upper steering ring nut 












and steering column 


M25x1.0 


2 


3 


0.3 


Ring nut 


Rear/front braking circuit: 












Front brake master cylinder and 


M6 X1.0 


2 


10 


1.0 


Socket head screw 


fastening bracket to handle bar 












Brake fluid tank (front bracket) 


M6 xl.O 


2 


10 


1.0 


Socket head screw 


Front brake master cylinder and brake hose 


M10 x 1.0 


1 


15 


1.5 


Joint 


Front brake caliper and brake hose 


M10x 1.0 


1 


15 


1.5 


Joint 


Front and rear brake fluid 












bleeder screw 


M10x1.0 


1 


6 


0.6 


Air bleeder 


Front brake caliper to front fork 


MlOx 1.5 


2 


50 


5.0 


Hexagonal head screw 
with flange 


Front wheel axle 


M16x 1.5 


1 


70 


7.0 


Axle 


Front wheel axle fastening bolt 


M8 xl.25 


1 


15 


1.5 


Socket head screw 


Front/rear brake disk and hub 


M8 X1.25 


6+3 


23 


2.3 


Socket thin head screw 


Footrest and rear brake master cylinder 


M6 xl.O 


2 


13 


1.3 


Hexagonal head screw 


Bracket and rear brake fluid tank 


M6 xl.O 


1 


4 


0.4 


Socket head screw 


Rear brake caliper and bracket 


M8 x 1 .25 


2 


23 


2.3 


Socket thin head screw 


Rear brake caliper and brake hose 


M10x1.0 


1 


15 


1.5 


Joint 


Rear brake master cylinder and brake hose 


M10x1.0 


1 


15 


1.5 


Joint 


Driven sprocket and hub clutch 


M8 x 1 .25 


6 


23 


2.3 


Hexagonal head screw 


Rear wheel axle nut 


M14X1.5 


1 


80 


8.0 


Axle + tocknut 


Shock absorber/rear arm: 












Rear arm/rear arm axle 












and main frame 


Ml8x 1.5 


1 


110 


11 


Axle -t- locknut 


Rear arm and connecting rods 


M10x 1.25 


1 


40 


4.0 


Boit + locknut 


Relay arm and connecting rods 


M10x t.25 


1 


40 


4,0 


Bolt + locknut 


Relay arm and frame 


M10x 1.25 


1 


40 


4.0 


Bolt + locknut 


Relay arm and shock absorber 


M10x 1.25 


1 


40 


4.0 


Boit -*- locknut 


Shock absorber and frame 


M10x1.25 


1 


40 


4.0 


Boit + locknut 


Chain guard seal and rear arm 


M6 xl.O 


1 


5 


0.5 


Hexagonal head screw 


Chain case and rear arm 


M6 xl.O 


2 


9 


0.9 


Hexagonal head screw 



GENERAL SPECIFICATIONS ABOUT TIGHTENING 

TORQUES/DEFINITION OF UNITS OF MEASUREMENT 



GENERAL SPECIFICATIONS 
ABOUT TIGHTENING TORQUES 

This table indicates the tightening torques for stand- 
ard attachments with ISO-pitch thread. Torque 
specifications for special components or units are 
indicated in the related sections of this rnanual- 
In order to avoid any damage, tighten those units 
with many fastenings by following a progressive 
cross sequence, until the final tightening torque 
is obtained. Unless otherwise specified, the tight- 
ening torques given are meant for clean and dry 
threads. All components must be at ambient tem- 
perature. 



SPEC 0F 




A: Distance between flat parts 
B: External thread diameter 



A 
(Nut) 


B 

(Bolt) 


General specification 
about tightening torques 


Nm 


mkg 


10 mm 


6 mm 


6 


0.6 


12 mm 


8 mm 


15 


1.5 


14 mm 


10 mm 


30 


3.0 


17 mm 


12 mm 


55 


5,5 


19 mm 


14 mm 


85 


8.5 


22 mm 


16 mm 


130 


13.0 



DEFINITION OF UNITS OF MEASUREMENT 



Unit 


Meaning 


Definition 


Measure 


mm 

cm 


millimetre 
centimetre 


10 -3 metres 
10 -2 metres 


Length 
Length 


kg 


kilogram 


!0 3 grams 


Weight 


N 


Newton 


1 kg x m/sec 2 


Force 


Nm 

mkg 


Newton-metre 
metre per kilo 


N x m 

mxkg 


Torque 
Torque 


Pa 
N/mm 


Paskal 
Newton per mm 


N/m 2 
N/mm 


Pressure 
Spring constant 


L 
cm 3 


Litre 

Cubic centimetres 


^~ 


Volume or capacity 


rpm 


Revolutions per minute 


^— 


Engine speed 



2-19 



2-20 



LUBRICATION POINTS AND LUBRICANT TYPE 



LUBRICATION POINTS AND LUBRICANT TYPE 
ENGINE 



Lubrication points {part name 



Oil seat edges (completely) 



Bearing retainer 



Rod pins 



Rod (big end) 



Pistons and piston rings 



Hub (balancer drive sprocket) 



Piston pins 



Valve stem and guide 



Oil seal (valve stem end) 



Rocker shaft and rocker arm 



Cam and bearing (camshaft) 



Rotor and rotor housing (oil pump) 



Disengagement control rod 



Primary driven gear and primary shaft 



Sliding gear (transmission) 



Free gear (transmission 



Shift forks and fork guide bar 



Gearshift cam and bearing (gearshift cam) 



Gearshift shaft 



Rod housing coupled surfaces 



Coupled surfaces (cylinder head and cylinder head cover) 



SPEC 0/ 




Lubricant type 



Si 



(3 



,(3 



(3 



Q 



(3 



,Q 



i(mJ 



'E 



Q 



(3 



O 



G 



'E 



E 






>l 



(3 



Bonding agent (rapid seal adhesive)® 
Yamaha bond No. 1215® 



Bonding agent (rapid seal adhesive}* 
Yamaha bond No. 121 



LUBRICATION POINTS AND LUBRICANT TYPE 



CHASSIS 



Lubrication points (part name) 



Gear unit (tachometer) 



Oil seal edges (completely) 



Wheel axie (front and rear wheels) 



Rear wheel hub and clutch 



Bearing brasses (rear arm) and relay arm 



Pivot rod (rear arm) 



Bearing brasses (rear shock absorber) 



Bearing brasses (shock arm and link) 



Bearing (shock arm and Jink) 



Pivot points (brake pedal and gearshift selector) 



Bearings (steeering column) 



Throttle grip end 



Pivot points (brake lever and clutch lever) 



Clutch cable end 



Pivot points (side stand) 



Bearing brasses (chain tensioner) 



Grease nipple (rear arm) 



Grease nipple (shock arm) 



Grease nipple (shock link) 



SPEC 


Pf 



Lubricant type 



2-21 



2-22 



LUBRICATION LAYOUT 

(1) Oil tank 

(2) Oil pump 

(3) Oil pump strainer (engine 



LUBRICATION LAYOUT 



[A] INTAKE 

[B] RETRIEVAL 



SPEC Pf 




(1) 


Camshaft 


(2) 


Oil delivery hose 


(3) 


Oil filter 


(4) 


Oil pump 


(5) 


Main driving shaft 


(6) 


Drive shaft 


(7) 


Oil hose 


(8) 


Oil delivery hose 



LUBRICATION LAYOUT 



SPEC pf 



[A] INTAKE 

[B] RETRIEVAL 





2-23 



2-24 



(1) Camshaft 

(2) Oil delivery hose 

(3) Oi! filter 

(4) Connecting rod pin 

(5) Main driving shaft 

(6) Secondary drive shaft 

(7) Drain plug 



LUBRICATION LAYOUT 



SPEC 09 




[A) INTAKE 

[B] RETRIEVAL 



(1) Oil delivery hose 

(2) Oi! filter 

(3) Oil pump 

(4) Transmission 

(5) Oil pump strainer 



LUBRICATION LAYOUT 



SPEC pf 



[A] INTAKE 

[B] RETRIEVAL 





2-25 



2-26 



COOLING LAYOUT 

(1) Thermostat 

(2) Radiator 

(3) Electric fan 

(4) Pump 

(5) Inlet hose 

(6) Outlet hose 



COOLING LAYOUT 



SPEC 


Pf 




SPEC 09 




2-27 



CABLES ROUTING „ Rectifier 

6. Clamp 



1. Clutch cable 

2. Fuse holder 

3. (-) cable 

4. Rear brake hose 

5. Regulator/ 



7. Rear taiilight 
connector 

8. Flasher relay 

9. C.D.I, unit 

10. Starter relay 



CABLES ROUTING 



11. Connector 

l2.(+)cable 

13. Fuel impulse pipe 

14.CIamp 

15. Recover/ tank 
breather pipe 

16. Coil 



spec Of 




17, Throttle cables 



\EM Cfr. page 2-32 



1. Recovery tank 

breather pipe 

2. Clamp 

3. Clutch cable 

4. Coil 

5. Cfamp 

6. Throttle cables 

7. Oil retrieval hose 



CABLES ROUTING 



8. Starter motor cabfe 

9. Battery (+) cable/ 
Starter relay 

1 0. Starter relay 

11. Flasher relay 

12. Taiilight connector 

13. Rear brake hose 

14. Battery 



15. Cables holder 

16. Side stand switch 

17. Breather pipes 
18.Cables holder 

19. Oil delivery hose 

20. Engine oil breather 
pipe (to engine oil 
tank) 



spec pf 



21. Odometer cable 
sleeve 

22. Odometer cable 

23. Recovery tank supply 
hose 





2-29 



2-30 



1. Number plate and 
direction indicator 

cables 

2. Rear brake hose 

3. Rear brake fluid 

reserve tank 

4. Regulator/Rectifier 

5. Clamp 

6. (-) cable 



7. Low fuel signal 
connector cable 

8. Air cleaner case 

9. Cable holder 
10. Cable holder 
11. Clutch cable 

12. Throttle cables 

13. Recovery tank 
supply hose 



CABLES ROUTING 



SPEC 09 




14. Clamp 

15. Front brake caliper 

16. Front brake hose 

17. Horn 

18- Cooling radiator fan 

connector 
19- Breather pipes 
20, Rear brake master 

cylinder 



21. Rear stop switch 

22. Rear brake supply 
hose 



CABLES ROUTING 



SPEC 0y 



1. Carburetor suction 
connection hose 

2- Clutch cable 

3. Clamp 

4- Fuel lap suction 
connection hose 

5. Low fuel signal 
connector cable 

6- Earth cable 

7- Battery bleeder 
pipe 



8. Fuel impulse 
pipe 

9. Fuel tank water 
discharge pipe 

10, Cables holder 

1 1 - Starter motor cable 

12- Recovery tank 

breather pipe 
13. Instrumentation 

lighting connector 

cabie 



14- Clamp 

15. Odometer cable 

16. Recovery tank 

supply pipe 

17. Front brake fluid 
supply hose 

18. Front stop switch 

cable 

19. Front brake hose 

20. Front lamps 
assembly cable 



21. Front brake hose and 
throttle cables 
holder 



8 



10 



11 12 13 14 




22 21 20 19 



18 17 16 15 




4 
5 

6 

7 



2-31 



2-32 



INSP 
ADJ 


pa 




CHAPTER 3° 
PERIODIC INSPECTION AND ADJUSTMENT 



PERIODIC MAINTENANCE/LUBRICATION INTERVALS B-15 

SEAT, FUEL TANK AND REAR COWLING B-16 

REMOVAL AND INSTALLATION B-16 

COWLING C-1 

REMOVAL AND INSTALLATION C-1 

ENGINE C-2 

VALVE CLEARANCE ADJUSTMENT C-2 

DRIVE CHAIN ADJUSTMENT C-3 

IDLE SPEED ADJUSTMENT C-3 

THROTTLE CABLE FREE PLAY ADJUSTMENT C-4 

SPARK PLUG INSPECTION C-4 

IGNITION TIMING CHECK C-5 

COMPRESSION INSPECTION C-6 

ENGINE OIL LEVEL CHECK C-7 

ENGINE OIL REPLACEMENT C-8 

ENGINE OIL PRESSURE CHECK C-10 

CLUTCH ADJUSTMENT C-10 

AIR FILTER CLEANING C-1 1 

SUCTION HOSE AND MANIFOLD INSPECTION C-1 1 

FUEL LINE INSPECTION C-12 

CRANKCASE VENTILATION HOSE INSPECTION C-12 

EXHAUST SYSTEM INSPECTION C-12 

CHECKING THE COOLANT LEVEL C-12 

CHANGING THE COOLANT C-13 

COOLING SYSTEM INSPECTION C-14 

CHASSIS C-15 

FRONT BRAKE ADJUSTMENT C-15 

REAR BRAKE ADJUSTMENT C-15 

BRAKE FLUID LEVEL CHECK C-16 

BRAKE PAD WEAR INSPECTION C-16 

BRAKE HOSING INSPECTION C-16 

BRAKE CIRCUIT BLEEDING D-1 

DRIVE CHAIN TIGHTNESS INSPECTION AND ADJUSTMENT D-1 

DRIVE CHAIN LUBRICATION D-2 

FRONT FORK INSPECTION AND ADJUSTMENT D-2 

SHOCK ABSORBER INSPECTION AND ADJUSTMENT D-3 



INSP 
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STEERING INSPECTION D-4 

TYRE INSPECTION D-5 

WHEEL INSPECTION D-6 

CABLE INSPECTION AND LUBRICATION D-6 

LEVER AND PEDAL LUBRICATION D-6 

SIDE STAND LUBRICATION D-6 

REAR SWING ARM LUBRICATION D-6 

ELECTRICALS D-6 

HEADLIGHT: LAMP REPLACEMENT AND SETTING D-6 

FUSE INSPECTION AND REPLACEMENT D-7 

BATTERY INSPECTION D-8 



PERIODIC MAINTENANCE/LUBRICATION INTERVALS 



INSP 
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PERIODIC INSPECTION AND ADJUSTMENT 



INTRODUCTION 

This chapter lists the procedures necessary to perform the recommended inspections and adjustments- 
Observance of these preventive maintenance procedures will ensure proper functioning and longer life for 
the vehicle. 

The need for general overhauls will also be considerably reduced. 

The information which follows applies to motorbikes already in use and new ones ready for sale- 
All maintenance personnel should be familiar with the instructions contained in this chapter, 

PERIODIC MAINTENANCE/LUBRICATION INTERVALS 



PART 


NOTES 


AFTER 

RUNNING 

1 ,000 km 

(600 mi) 


EVERY 


6,000 km 
(4,000 mi) 

or 6 months 


12,000 km 

(8,000 mi) 
or 12 months 


Valves* 


Check valve clearance. 
Adjust if necessary. 


O 


O 


O 


Spark plug 


Check conditions- 
Clean or replace if necessary. 


O 


O 


O 


Air filter 


Clean. Replace if necessary. 




o 


o 


Carburetor* 


Check idle speed 
and starter- 
Adjust if necessary- 


o 


o 


o 


Fuel line* 


Check fuel pipes condition- 
Replace if necessary. 




o 





Engine oil 


Replace (heat engine prior to 
dumping oil). 


o 


o 


o 


Engine oil filter* 


Replace filter element- 


o 


o 





Cooling system 


Check coolant leakage- 
Repair if necessary. 
Replace coolant every 
24,000 kms (16,000 mi) 
or 24 months 




o 


o 


Brakes* 


Check functiontng/fluid/Ieakage. 
See NOTE, 
Correct if necessary. 




o 


o 


Clutch 


Check functioning. 
Adjust if necessary. 






o 





Rear arm 
axle* 


Check that the rear arm unit is not 
loose- 
Correct if necessary. 
Grease moderately/** 


o 


o 



PERIODIC MAINTENANCE/LUBRICATION INTERVALS 



INSP 
ADJ 


1*9 



PART 


NOTES 


AFTER 
RUNNING 
1 ,000 km 

(600 mi) 


EVERY 


6,000 km 

(4,000 mi) 

or 6 months 


12,000 km 

(8,000 mi) 
or 1 2 months 


Rear suspension 
connection pins** 


Check functioning. 

Grease 

moderately.*** 




O 


O 


■ » m !■ ■ ■ ■ i 

Wheels* 


Check balancing/damage/run-out. 
Repair if necessary. 




O 


O 


Wheel bearings* 


Check bearing clearance/damage. 
Replace if necessary. 




O 


O 


Steering bearings* 


Check bearing clearance. 
Correct if necessary. 
Lubricate moderately every 
24,000 km (1 6,000 mi) or 24 months 


O 




O 


Front fork* 


Check functioning/oil leakage- 
Repair if necessary. 




o 


O 


■ hi ^m^— 

Rear shock 
absorber* 


Check functioning/oil leakage. 
Repair if necessary. 




o 


O 


Drive chain 


Check chain slack/alignment. 

Adjust if necessary. 

Clean and lubricate the chain. 


Every 500 km (300 mi) 


Fittings/ 
fasteners* 


Check all frame fittings and fasteners. 
Tighten if necessary. 


O 





O 


Side stand* 


Check functioning. 
Repair if necessary. 


O 


o 





Side stand 

switch* 


Check functioning. 

Clean or replace if necessary. 





o 


o 



** 



*** 



Maintenance work on these elements should be performed by a Yamaha dealer. 
Medium-consistency bearing grease- 
Lithium soap-based grease. 



NOTE: . . . - . 

Brake fluid replacement: 

1 . After disassembling the master and caliper cylinders, replace the brake fluid. Check the level of the fluid 
regularly and top up if necessary. 

2. Replace the gaskets inside the master and caliper cylinders every 2 years. 

3. Replace the brake hoses every four years or when they are cracked or damaged. 



3-1 



3-2 



SEAT, FUEL TANK AND REAR COWLING 



INSP 
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SEAT, FUEL TANK AND REAR COWLING 




SEAT, FUEL TANK AND REAR COWLING 



INSP 
ADJ 


HI 



JOB INSTRUCTION CHART 



Order 


Job name/Part name 


Q.ty 


Remarks 




Removal of seat, fuel tank 
and rear cowling 




Remove the parts in the order. 
The seat removed, fuel tank and rear cowl- 
ing may be removed Individually. 


1 

2 

3 
4 
5 


Key 

Seat 

Screw 
Screw 
Fuel pipe 


1 
1 

1 
1 
1 


NOTF; 


Turn the key anticlockwise to remove the seat 
and clockwise to reinstall it. 


NHTF* 

Before removing the fuel pipe, close the tap by 
turning the ring nut screw tightly clockwise. 


6 


Suction pressure intake pipe 


1 




7 


Low fuel warning light 
connector 


1 




8 


Tap water discharge pipe 


1 




9 


Fuel tank 


1 




10 


Screw 


2 




11 
12 


Pressure fasteners 
Pressure fasteners 


2 

2 


NOTE: 

Press down the rear cowling extremities- 


MOTP- 

Widen the rear cowling body sides carefully. 


13 
14 


Taillight connector 
Rear cowling 


1 
1 


Reverse the removal procedure for in- 
stallation. 



3-3 



3-4 



COWLING 



INSP 
ADJ 


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COWLING 



COWLING 




INSP 
ADJ 


ea 



JOB INSTRUCTION CHART 



Order 


Job name/Part name 


Q.ty 


Remarks 




Removal of cowling 




Remove the parts in the order shown. 
The right and left semifairings may be 
removed separately. 


1 


Nut 


2 




2 


Rear view mirror (R) 


1 




3 


Screw 


1 




4 


Screw 


1 




5 


Screw 


2 




6 


Side panel (R) 


1 




7 


Nut 


2 




8 


Rear view mirror (L) 


1 




9 


Screw 


1 




10 


Screw 


1 




11 


Screw 


2 




12 


Side panel (L) 


1 




13 


Window front 


1 




14 


Screw 


1 




15 


Screw 


2 




16 


Air flap 


1 


Reverse the removal procedure (or instal- 
lation. 



3-5 



3-6 



VALVE CLEARANCE ADJUSTMENT 






' * If*- ', "\ 



■c. 



- ,:<;' 










!,' */ 



""- ^-Mk^'JSfj 






.i. 









__— -© 




fin 




WC^ 



^ 



^ 







. mj:?»c^»u 



V' «t& 



A* 



m#mr -, 



^ 



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X 



*- ^ * 






v- 1 : 



^ 



INSP 
ADJ 


pa 




ENGINE 



VALVE CLEARANCE ADJUSTMENT 



NOTE: 



Valve clearance must be adjusted when the 

engine is at ambient temperature. 

Adjust valve clearance with the piston under 

compression at top dead centre. 



CAUTION: 



When removing the spark pfug and tappet cover, 
be careful not to drop foreign objects inside the 
engine. 



A WARNING 



Hold the motorcycle firmly in place to prevent it 
falling over during the operation. 

1. Remove: 

• Seat 

• Fuel tank 

• Cowling 

• See the section "SEAT, FUEL TANK AND 
REAR COWLING" and "COWLING". 

2- Remove: 

• Screws (1) (2) (fastening the radiator) 

• Screw (3) 

3. Remove: 

• Radiator (4) (disconnect the electric 
connector) 

4. Loosen: 

• Carburetor manifold clamps (5) 

5. Remove: 

• Air cleaner case assembly (6) 

• Air panel (7) 



VALVE CLEARANCE ADJUSTMENT 



INSP 
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9. Turn: 

• Driving shaft anticlockwise (using a 
wrench) 



10. Align: 

• Reference mark 'T f on the flywheel (1) 
with the fixed reference mark on the crank- 
case (2) 

NOTE: , ,, „ . , 

Check that the piston is under compression at top 
dead centre. 

(3) Ignition timing reference mark 

11. Check: 

• Valve clearance using the special gauge 

(T) 

Out of specification -> Adjust. 




^ 



Valve clearance (cold): 
Suction: 

0.10-0.15 mm 
Exhaust: 
0.15-0.20 mm 



12. Adjust: 

• Valve clearance 



Adjustment: 

• Loosen the lock nut (1). 

• Fit a thickness gauge (2) between the rocker arm 
and the valve stem. 

• Turn the adjuster (3) clockwise or anticlockwise 
using the special tool (4) to obtain the required 
clearance. 









11 







' : ''^' 



** Wi 



■\ 




v 






O_0£ A 



% 




L.J 



6. Disconnect: 

• Spark plug cap 

7. Remove: 

• Spark plug 

• Tappet cover (8) (suction) 

• Tappet covers (9) (exhaust) 

8. Remove: 

• Cap (10) 

• Cap (11) 





Special tool: 
P/N. YM-08035 
P/N. 90890-01311 



Holding the adjuster firmly in place, lock tighten 
lock nut. 




Lock nut: 
14Nm{1.4mkg) 



3-7 



3-8 



VALVE CLEARANCE ADJUSTMENT 



INSP 
ADJ 


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DRIVE CHAIN ADJUSTMENT/ 
IDLE SPEED ADJUSTMENT 



INSP 
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• Measure valve clearance. 

• If the clearance is incorrect, repeat the previous 
steps to achieve the required value. 

13. Reassemble: 

Reverse the removal procedure. 

• Caps 

• Tappet cover (suction) 

• Tappet covers (exhaust) 

• Spark plug 





\ 


Tappet cover (exhaust): 
12Nm(1.2mkg) 

Bolt {tappet cover-suction): 
10Nm(1.0mkg) 

Spark plug: 
18 Nm (1.8 mkg) 





14. Connect: 

• Spark plug cap 

15. Reassemble: 

Air panel 

Air cleaner case assembly 

Radiator 

Thermostat assembly 

Fue! tank 

Seat 

Cowling 

See the section "SEAT, FUEL TANK AND 

REAR COWLING" and "COWLING". 





Bolt (air cleaner case): 
5 Nm(0.5 mkg) 

Carburetor manifold clamp (L): 
2 Nm (0.2 mkg) 

Carburetor manifold clamp (R): 
5 Nm (0.5 mkg) 

Bolt (radiator); 

10 Nm (1.0 mkg) 

Bolt (thermostat assembly): 
10 Nm (1.0 mkg) 

Screws (fuel tank): 
10 Nm (1.0 mkg) 

Screws (cowling): 
10 Nm (1.0 mkg) 




{£' - "'"*****4*^ 



DRIVE CHAIN ADJUSTMENT 

The drive chain does not need to be adjusted. 



IDLE SPEED ADJUSTMENT 

1 . Start the engine and let it heat 

2. Connect: 

• The inductive engine speed indicator to 

the spark plug cable. 




Inductive engine speed indicator: 
P/N. YU-08036-A 
P/N, 90890-03113 



3. Check; 

• The engine idle speed 

• Out of specification -> Adjust. 



c\ 



Engine idle speed: 
1,250-1,350 rpm 



4. Adjust: 

• Engine idle speed 



* * ■ * * * * * 



#*#■******* 



* * * ** 



Adjustment: 

• Turn the air adjusting screw (1 ) until it is slightly 

locked. 

• Unscrew the air adjusting screw by 3 turns 
aprox. 




Air adjusting screw: 
Unscrew by 3 turns aprox. 



Turn the throttle stop knob (2) either way to 
obtain the engine idle speed required. 



Screwing 


Increases idle speed 


Unscrewing 


Decreases idle speed 



5. Disconnect; 

• Inductive engine speed indicator 

6. Adjust: 

• Throttle cable free play 

See the section "THROTTLE CABLE 

FREE PLAY ADJUSTMENT". 




^ 



Throttle cable free ptay: 
3-5 mm 



3-9 



3-10 



THROTTLE CABLE FREE PLAY ADJUSTMENT 



INSP 
ADJ 


pa 






THROTTLE CABLE FREE PLAY 
ADJUSTMENT 



NOTE: __ 

Before adjusting the throttle cable free play, adjust 
the engine idle speed. 



1. Check: 

• Throttle cable free play (A) 

♦ Out of specification ~* Adjust. 




2. 



Remove: 

• Seat 

• Fuel tank 

• Air cleaner case 

• Air panel 

• See the section "SEAT, FUEL TANK AND 
REAR COWLING" and "VALVE CLEAR- 
ANCE ADJUSTMENT". 



3. Adjust: 

* Throttle cable free play 



Adjustment: 

• Loosen the 1 throttle cable (2) lock nuts (1). 

• Turn the adjuster (3) clockwise or anticlockwise 
to obtain the required free play. 

• If after loosening the adjuster by 5 mm, the free 
play is still not correct, tighten the adjuster (4) on 
the 2 throttle cable (5) once more. 

• Tighten the lock nuts. 



1), (6) Lock nuts 



* * 



* ft 



R ft ft 



ft A ft * 



THROTTLE CABLE FREE PLAY ADJUSTMENT/ 

SPARK PLUG INSPECTION 

4. Reassemble: 

• Air panel 

• Air cleaner case 

• Fuel tank 

• Seat 



INSP 
ADJ 


pa 




Bolt (air cleaner case): 

5 Nm (0.5 mkg) 
Carburetor manifold clamp <L): 

2 Nm (0.2 mkg) 
Carburetor manifold clamp (R): 

5 Nm (0.5 mkg) 
Screws {fuel tank): 

10 Nm (1.0 mkg) 



SPARK PLUG INSPECTION 

1. Remove: 

• Seat 

• Fuel tank 

• Air cleaner case 

• Air panel 

• See the section "SEAT, FUEL TANK AND 
REAR COWLING" and "VALVE CLEAR- 
ANCE ADJUSTMENT' 

2. Disconnect: 

• Spark plug cap 

3. Remove: 

• Spark plug 

CAUTION: 



When removingthespark plug, becarefulnotto 
drop foreign objects or dirt inside the engine. 

4. Inspect: 

• Type of spark plug 
Incorrect -> Replace. 




Standard sparkplug: 

DPR8EA-9 (NGK), DPR9EA-9 (NGK) 



5. 



Inspect: 

• Electrodes (1 
Wear/Damage -> Replace. 

• Insulator (2) 

Abnormal insulator colour -> Replace the 

spark plug. 

Normal insulator (2) colour is light tan. 



3-11 



3-12 



SPARK PLUG INSPECTION 




INSP 
ADJ 


ra 




6. Clean: 

• The spark plug with a suitable tool and a 
steel brush 

7. Measure: 

• Spark plug electrode gap {a) 
Use a wire or thickness gauge 
Out of specification -* Regap. 



m 



Electrode gap: 
0.8-0.9 mm 



8. Tight: 

♦ Spark pfug 




Spark plug: 

18Nm(1.8mkg) 



NOTES: 



Before installing the spark plug, clean the surface 

and thread. 

Tighten the spark plug by hand before torquing to 

specification. 



9. Connect: 

• Spark plug cap 

10. Install: 

• Air panel 

• Air cleaner case 

• Fuel tank 

• Seat 



\ 


Bolt (air cleaner case): 


5 Nm (0.5 mkg) 
Carburetor manifold clamp (L): 






2 Nm (0.2 mkg) 




Carburetor manifold clamp (R); 




5 Nm (0.5 mkg) 




Screws (fuel tank): 




10 Nm (1.0 mkg) 













\ 






^* ,., * * 



ip c c ^ 






IGNITION TIMING CHECK 



INSP 
ADJ 


pa 




IGNITION TIMING CHECK 



NOTE: 



Before checking the ignition timing adjust thethrottle 
cable free play and the engine idle speed. 

1 . Start the engine and let it heat. 

2. Connect: 

• Inductive rev. counter 

• Stroboscopic lamp to spark plug cable 




Inductive engine speed indicator: 
P/N. YU-08036-A 
P/N. 90890-03113 

Stroboscopic lamp; 
P/N. YM-33277-A 
P/N. 90890-03141 



3. Remove: 
• Cap(1) 

CAUTION: 



In certain conditions, the oi! might spray out 
when the cap is removed. Be careful therefore 
when removing the cap. 



4. Check: 

• Advance ignition 



* * a- * 



Check: 

• Heat engine and let it run to the number of revs 
required. 



C\ 



Engine speed: 
1,300 rpm 



* Check that the firm reference (1 ) is in the field of 
reference mobile (2) on the flywheel. 
Incorrect ignition timing -» Check the ignition coit 
unit. 

NOTE: _____™„ m . 



Ignition timing cannot be adjusted- 



******** 



**>*■«*********# ***■■« 



5. 



6, 



Install: 

• Cap 
Remove: 

• Stroboscopic lamp 

• Inductive engine speed indicator 



3-13 



3-14 



COMPRESSION INSPECTION 



INSP 
ADJ 


P9 





COMPRESSION INSPECTION 



NOTE; 



insufficient compression causes a loss of perform- 
ance. 



A WARNING 



Set the motorcycle firmly in place to prevent it 
failing during the operation. 

1. Remove: 
Seat 
Fuel tank 
Air cleaner case 
Air panel 

See the section "SEAT, FUEL TANK AND 
REAR COWLING" and "VALVE CLEAR- 
ANCE ADJUSTMENT. 

2. Check; 

• Valve clearance 
Out of specification -* Adjust. 
See the section "VALVE CLEARANCE 
ADJUSTMENT". 

3. Install: 

• Auxiliary fuel tank 

4. Start the engine and let it heat 

• Stop the engine 

5. Disconnect: 

• Spark plug cap 

6. Remove: 

• Spark plug 



CAUTION: 



When removing the spark plug, be careful to 
prevent foreign bodies from dropping inside 
the engine. 



7. Apply: 

• Pressure gauge (1 

• Adapter (2) 




Pressure gauge: 
P/N. YU-33223 
P/N. 90890-03081 

Adapter: 

P/N. YU-33223-3 
P/N. 90890-04082 



COMPRESSION ADJUSTMENT 



INSP 
ADJ 


em 



8. Check: 

• Pressure under compression 



Check: 

• Check that the battery is fully charged and revthe 
engine with the starter. Hold down the accelera- 
tor until the reading on the pressure gauge is 
stable. 



4 WARNING 



Wh ile operating the starter, disconnect the spark 
plug cap to avoid sparks. 

• Compare the pressure reading with those in the 
table. 



Pressure under compression (at sealevel): 


Standard: 




1,100 kPa{11 kg/cm ? , 


156 psi) 


Minimum: 




900 kPa (9 kg/cm 2 , 128 psi) 


Maximum: 




1 ,200 kPa (1 2 kg/cm 2 , 


171 psi) 



• If the pressure reading is lower than minimum; 

1 ) Add a few drops of oil to the cylinder through 
the hole in the spark plug. 

2) Measure the compression again. 

3) Compare the new reading with the first, then 
proceed according to the indications in the 
table. 



Pressure under compression 
(after adding oil to the cylinder) 


Reading 


Diagnosis 


Pressure higher 
than before. 


Piston worn or 
damaged. 


Pressure same as 
before. 


Cylinder head or 
piston rings, valves, 
gaskets may be 
faulty. 


Pressureabove maxi- 
mum value. 


Inspect cylinder head, 
valve surfaces, piston 
rim to check for car- 
bon deposits. 



9. Remove; 

• Auxiliary fuef tank 

• Pressure gauge (with adapter) 

10. Install: 

• Spark plug 

See the section "SPARK PLUG INSPEC- 
TION". 




Spark plug 
18Nm(1.8mkg) 



1 1 . Connect: 

• Spark plug cap 

12, Reassemble; 

• Air panel 

• Air cleaner case 

• Fuel tank 

• Seat 




Bolt (air cleaner case): 

5 Nm (0.5 mkg) 
Carburetor manifold clamp (L): 

2 Nm (0.2 mkg) 
Carburetor manifold clamp (R): 

5 Nm (0.5 mkg) 
Screws (fuel tank): 

10Nm(1.0 mkg) 



3-15 



3-16 



ENGINE OIL LEVEL CHECK 



ENGINE OIL LEVEL CHECK 



INSP 
ADJ 


WA 



CAUTION: 



Do not put additives into the engine oil. The 
latter also lubricates the clutch and additives 
might cause it to slide. 




ENGINE OIL LEVEL CHECK 



INSP 
ADJ 


Wtk 



6. Start the engine and heal until the temperatu- 
re reaches 60°C or thereabouts. 



CAUTION: 



Never start the engine when the oil tank is 
empty- 



WARNING 




Never remove the oil tank cap when the engine 
is hot. The boiling oil might spill over, causing 
burns. Watt for the oil to cool to at least 60° or 
thereabouts. 

This model is fitted with a dry crankcase lubrication 

system. A feed pump delivers oil to the engine; after 
fully lubricating the latter, the oil is returned to the 
tank by a scavenge pump. The oil level must 

therefore be checked in the oil tank. 



1. Set the motorcycle level and hold it upright. 

2. Unscrew the oil tank cap (1 ) and clean the cap 
stem. 

3. Insert the cap sucker rod into the tank. Do not 
unscrew; simply place on the filler. 

4. Pull out the rod and check the oil level. The 
latter must be between the minimum (3) and 
maximum (2) levels. 



NOTE: ____ 

To check the oil level, place the cap with the rod on 

the filler without screwing it. 

For an exact check, hold the cycle upright. 



7. Run the engine at idle speed for about 10 
seconds, holding the motorcycle firmly up- 
right. Turn off the engine and add oil up to the 
maximum level. 

8. Replace the oil tank cap. 




Oil capacity; 
Total: 
3.0 litres 

Periodic oil change: 
2.6 litres 

With oH filter change: 
11 litres 



If the oil level is below minimum -» Add oil up to 

minimum level. 



■X} 



Recommended engine oil: 
SHELL SUPER 4TX 20W/50 



5. Reassemble the oil tank cap. 



3-17 



3-18 



ENGINE OIL REPLACEMENT 



INSP 
ADJ 


pa 



ENGINE OIL REPLACEMENT 



CAUTION; 



Do not put additives into the engine oil. The 
latter also lubricates the clutch and additives 
might cause ft to slide. 



A WARNING 



Remove the oif tank tap carefully when the 
engine is hot: the hot oi! can spout out injuring 
the user. 




ENGINE OIL REPLACEMENT 



INSP 
ADJ 


1*9 



7. Reassemble: 

• Filter cover screws 

• Oil sump drainage bolt 

• Oil inlet hose fastening screw 




Oil sump drainage bolt (engine): 
30 Nm (3.0 mkg) 

Oil inlet hose fastening screw: 
30 Nm (3.0 mkg) 

Filter cover screw: 
10 Nm {1.0 mkg) 





Engine oil replacement (without replacing oil 
filter) 

1 . Start the engine, heat it lor a few minutes then 
switch off. 

2. Place a container under the engine and oi 
tank. 



8. FiJt: 



3. Remove: 

Oil tank cap (1) 

Oil inlet hose fastening screw (2) 
Oil sump drainage bolt (3) 
Oil filter cover bleeder screw (4) 
Filter cover screw (5) 



NOTE: „ 

The oil filter cover is secured by three screws. The 
lowest one should be removed first, so that the filter 
will drain. 



4. Drain: 

• Engine oil completely 

5. Replace; 

• Oil inlet hose gaskets 

• Oil sump drainage bolt gasket (engine 

6. Inspect: 

• All gaskets 
Damaged -» Replace. 



Oil tank 

Oil filter housing (by bleeder hole) 



•tt 



Recommended engine oil: 
SHELL SUPER 4TX 20W/50 

Oil capacity: 
Periodic change 2.S litres 



CAUTION: 



Be careful to prevent forefgn bodies dropping 
into the engine. 

Do not put additives into the engine oil. The 
latter also lubricates the clutch and the addi- 
tives may make it slide. 

9. Install: 

♦ Oil filler cover bleeder screw 




Oil filter cover bleeder screw: 
5 Nm (0.5 mkg) 



10. Check: 

• Oil level 

See the section "ENGINE OIL LEVEL 
CHECK". 

• Oil pressure 
Seethesection"ENGINEOILPRESSURE 
CHECK". 

• Oil leakage 

11. Install: 

• Oil tank cap 



3-19 



3-20 



ENGINE OIL REPLACEMENT 



INSP 
ADJ 


PI 








fften 




C'i") 



v: 




vi 



A>OUTSlDE! 






: r B7iNSiDEl 



V™ 



Engine oil replacement (with oil filter replace- 
ment) 

1 . Start the engine, heat it up for a few minutes, 
then turn it off. 

2. Place a container under the engine and oil 
tank. 

3. Remove: 
Oil tank cap (1) 

Oil inlet hose fastening screw (2) 
Oil sump drainage bolt (3) 
Oil filter cover bleeder screw (4) 
Filter cover screws (5) 



NOTE: 

The oil filter cover is fastened with three screws. 
The lower screw must be removed first to allow the 
filter to drain. 



4. Drain: 

• Engine oil completely 

5. Remove: 
Oii filter cover (1 
Oil filter (2) 



6. 



7. 



Replace: 

Oil inlet gaskets 

Oil sump drainage bolt gasket (engine 

Inspect: 

All gaskets 

0-ring(1) 

Damaged -> Replace. 



8. Reassemble; 

• Oil filter (1) (new) 

CAUTION: 



Install the new oil filter as shown; 

[A] OUTER 

[B] INNER 

• Oil filter cover screws 

• Oil sump drainage screw 

• Oil inlet hose screw 



ENGINE OIL REPLACEMENT 



INSP 
ADJ 


ra 




Oil sump drainage screw (engine): 
30Nm{3.0 mkg) 

Oil inlet hose screw: 
30 Nm (3.0 mkg) 

Oil filter cover screws: 
10 Nm (1.0 mkg) 



9. Fill: 



Oil tank 

Oil filter housing (by bleeder hole) 




Recommended engine oil: 
SHELL SUPER 4TX 20W/S0 

Oil capacity: 
Total: 
3.0 litres 

Periodic oil change 

(with oil filter replacement): 

2.7 litres 



CAUTION: 



Be careful to prevent foreign bodies dropping 
into the engine crankcase. 
Do not add additives to the engine oi I . The latter 
also I ubricates the clutch and the additives may 
make it slide. 



10. Install: 

• Oil filter cover bleeder screw 




Oil filter cover bleeder screw: 
5 Nm (0.5 mkg) 



11. Check: 

« Oil level 

See the section "ENGINE OIL LEVEL 
CHECK". 

• Oil pressure 
Seethesection H ENGINEOILPRESSURE 
CHECK". 

• Oil leakage 

12, Install: 

• Oil lank cap 



3-21 



3-22 



ENGINE OIL PRESSURE CHECK 



INSP 
ADJ 


pa 








ENGINE OIL PRESSURE CHECK 

1. Remove: 

• Bleeder screw (1) 

2. Start the engine and let it run at idle speed until 
oil flows out of the bleeder hole. 

3. Inspect: 

♦ Conditions of oil at bleeder hole 

Oil leakage -> Oil pressure is correct. 
No leakage -* Oil pressure insufficient. 

CAUTION: 




If the oil does notflow out after one minute, stop 
the engine immediately to prevent seizure. 

4. Tighten: 

• Bleeder screw 




Bleeder screw; 
5 Nm(0.5 mkg) 





CLUTCH ADJUSTMENT 



INSP 
ADJ 


P3 



CLUTCH ADJUSTMENT 

Cable free play adjustment 

1. Check: 

• Clutch free play adjustment (A) 
Out of specification ■* Adjust. 




Free play (at the lever end): 
10- 15 mm 



2. Adjust: 

• Clutch cable free play 



Adjustment: 

♦ Loosen lock nut (1). 

• Turn the adjuster (2) either way to obtain correct 
free play. 

# Tighten lock nut after adjustment. 

• If free play is still incorrect, turn the crankcase 
adjusterfoilowing the same procedure described 
for the handle bar adjuster. 

(3) Lock nut 

(4) Adjuster 



NOTE: 

After adjustment, recheck lever free play to make 
sure that it works smoothly and progressively. 
If it is impossible to obtain the required adjustment 
or if the clutch does not work properly, adjust the 
internal mechanism. 



3-23 



3-24 




AIR FILTER CLEANING 



INSP 
ADJ 


ra 




AIR FILTER CLEANING 

1. Remove: 

• Seat 

• Fuef tank 

See the section "SEAT, FUEL TANK AND 
REAR COWLING". 

2. Unscrew: 

• Filter case cover screw 

3. Remove: 

• Filler case cover 

4. Pull out: 

• Filter element (tap to clean) 



AIR FILTER CLEANING/ 
SUCTION HOSE AND MANIFOLD INSPECTION 



INSP 
ADJ 


WSk 




9. Inspect: 

• Transparent sleeve (1) (on the filter case 
bottom) 

Water and/or dirt -> Clean the sleeve and 

the filter case. 

10. Reassemble: 

• Fuel tank 

• Seat 

See the section "SEAT, FUEL TANK AND 
REAR COWLING". 




Fuel tank screws: 
10Nm{1.0mkg) 



CAUTION: 



The engine must never be started without the 
air filter element, as this would cause undue 
wear and tear of the piston and/or cylinder. Use 
of the engine without the filter element modifies 
the carburation, causing poor performance and 
overheating. 



5. Inspect: 

• Fitter element 
Damaged -* Replace. 

6. Clean: 

• Filter element by blowing compressed air 
from the small metal net side. 

7. install: 

• Filter element (in the filter case) 

• Filter case cover 

NOTE: 

When installing the filter case cover, be sure that 

the seal is mounted to prevent air from entering. 



8. Tighten: 

* Filter case cover fastening screws 




A 



Filter casecoverfastening screws: 
5Nm (0.5 mkg) 




SUCTION HOSE AND 
MANIFOLD INSPECTION 

1. Remove: 

• Seat 

• Fuel tank 

• Air filter case 

See the section "SEAT, FUEL TANK AND 
REAR COWLING" and "VALVE 
CLEARANCE ADJUSTMENT" 

2. Inspect: 

• Suction hoses and manrfolds (1) 
Cracked/Damaged -> Replace. 




Screw (2) (carburetor manifold): 
10 Nm (1.0 mkg) 

Screw (4) (flange L): 
2 Nm {0.2 mkg) 

Screw (5) {flange R): 
5 Nm{0.5 mkg) 



3. Reassemble: 

• Air filter case 

• Fuel tank 

• Seat 




Bolt {air filter case): 
5 Nm (0.5 mkg) 

Screws (fuel tank): 
10 Nm (1.0 mkg) 



3-25 



3-26 



FUEL LINE INSPECTION/ 
CRANKCASE VENTILATION HOSE INSPECTION/ 

EXHAUST SYSTEM INSPECTION 



INSP 
ADJ 


pa 




CHECKING THE COOLANT LEVEL 



INSP 
ADJ 


ra 




^hShi 




FUEL LINE INSPECTION 

1 . Remove; 

• Seat 

• Fuel tank 

See the section "SEAT, FUEL TANK AND 
REAR COWLING". 

2. Inspect; 

• Fuel pipe (1) 

• Suction pipe (2) 

• Pipe from fuel tap (3) to suction assembly 
Cracked/Damaged -> Replace. 

3. Reassemble: 

• Fuel tank 

• Seat 





Fuel tank screws: 
10 Nm (1.0 mkg) 



CRANKCASE VENTILATION HOSE 
INSPECTION 

1. Inspect: 

• Crankcase ventilation hose (1 

Cracked/Damaged -* Replace 



CHECKING THE COOLANT LEVEL 

1. Set the motorcycle level and hold it upright. 

2. Check: 

• Coolant level on the reservoir tank (1 ). 
The coolant level must be between "LOW 
(3) and "FULL" (2) references. 
Level below the "LOW mark -» Add the 
coolant to the "FULL" mark. 

NOTE: „ „ 

(3) "LOW" and (2) "FULL" references on the reser- 
voir tank interna! side are visible even if the side 
panels are mounted. 




Recommended coolant: 

High quality ethylene glycol antifreeze 
solution containing corrosion inhibitors for 
aluminium engines. 

Coolant and water mixed ratio: 50%-50% 
Total amount: 1.4 litres 
Reservoir tank capacity: 0.55 litres 
From «LOW» to «FULL» level: 0.210 litres 







5 






^ } 


4 


3 r 

J '« 


^ 3 / / 

/ /**** 2 






,>>_/ 


I 

i ' 

i | 

■ ■ 


1 >' * 


^ 6 


1 M 


1 


^,3 


1 ' 
1 1 

r r 




■4 


3 

i 




3 9 


' 7^° 




EXHAUST SYSTEM INSPECTION 

1 . Inspect; 

• Exhaust pipe (1) 

• Silencer (2) 

Cracks/Damage -» Replace. 

• Gaskets (3) 

Exhaust gas leakage -> Replace. 

2. Check: 

• Tightening torques 



CAUTION: 



Nut (4) (exhaust pipe): 
10 Nm (1.0 mkg) 

Screw (5) (silencer): 
40 Nm (4.0 mkg) 

Bolt (6) (9) (flange): 

10 Nm(1.0 mkg) 

Screw (7) (exhaust pipe to bracket): 
23 Nm (2.3 mkg) 

Nuts (8) (Silent-block): 
23 Nm (2.3 mkg) 



Hardwaterorsaftwaterisharmfultotheengine. 
Use boiled or distilled water if soft water is not 
available* 



3. Start the engine and let it heat. 

4. Turn off the engine and wait for a few minutes. 

5. Recheck the level of the coolant. 



3-27 



3-28 



CHANGING THE COOLANT 



INSP 
ADJ 


WJk 






CHANGING THE COOLANT 



A WARNING 



Replace the coolant when the engine is cold to 
avoid the risk of burns. 

1. Remove: 

♦ Side panels of the cowling 
See the section "COWLING* 

2. Remove: 

♦ Thermostat cap {1) 



A WARNING 



Do not remove the thermostat cap when the 
engine and/or the radiator are hot. Scalding hot 
fluid and steam may be blow out under pres- 
sure, which could cause serious injury. When 
the engine has cooled, open the cap by the 
following procedure: place a thick rag, like a 
towel, over the cap, slowly rotate the cap 
counterclockwise to the detent This procedure 
allows any residual pressure to escape. When 
the hissing sound has stopped, press down on 

the cap while turning counterclockwise and 
remove it. 



3. Place: 

• Container under the engine 

4. Remove: 

• Drain bolt (2) from the water pump case 



5. Detach: 

• Pipe (3) from the base of the reservoir 
tank 

6. Drain: 

• Reservoir tank 

• All the cooling circuit 

• Engine 




CHANGING THE COOLANT 



INSP 
ADJ 


WSk 



7. Wash: 

* All the cooling circuit 

Use tap water 

8. Inspect: 

• Gasket of drain bolt 
Damaged -* Replace. 

9. install: 

♦ Drain bolt and gasket 




Drain bolt (water pump): 
10Nm{1.0mkg) 



10. Replace: 

• Supply pipe to the reservoir tank 



11. Fill: 



Cooling circuit (through the filler of thermo- 
stat assy) 




Recommended coolant: 

High quality ethylene glycol antifreeze 
solution containing corrosion inhibitors for 
aluminium engines. 

Coolant and water mixed ratio: 50%-50% 
Total amount: 1.4 litres 
Reservoir tank capacity: 0.55 litres 
From «LOW» to «FULL» level: 0,210 litres 



CAUTION: 



Hard wateror saltwater is harmful totheengfne* 
Use boiled or distilled water if soft water is not 
available. 

12. Install: 

• Thermostat assy cap 

13. Run the engine for a few minutes, then remove 
the thermostat assy cap and fill again the 
cooling circuit. 

14. install: 

• Thermostat assy cap 



3-29 



3-30 



CHANGING THE COOLANT 



INSP 
ADJ 


pa 



15. Fill; 

• Reservoir tank {up to "FULL" level) 

1 6. Start the engine and let it warm up for several 
minutes. 

17. Check: 

• Coolant level 

See the section "CHECKING THE 
COOLANT LEVEL*. 

18. Inspect: 

• All the cooling circuit 
Leakage -> Repair. 

See the section "COOLING CIRCUIT 
INSPECTION". 

19. Reassemble: 

• Side panels of the cowling 
See the section "COWLING" 1 




Screws (side panels of cowling): 
10Nm(l.0mkg) 



Notes on using the coolant: 

♦ The coolant is harmful to the health and must be 
used with care. 



A WARNING 



If the coolant enters into contact with the 

eyes, wash them with water and calf a doctor. 

If you should swallow the coolant, try to be 

sick and go to a doctor immediately. 

If the coolant enters into contact with clothes 

wash them immediately with water, then with 

soap. 




COOLING CIRCUIT INSPECTION 



INSP 
ADJ 


pa 




COOLING CIRCUIT INSPECTION 

1, Inspect: 

• Radiator (1) 

• Hose (2) (water pump-radiator) 

• Hoses (3) (cylinder-thermostat) 

• Hose (4) (thermostat-filler) 

• Hose (5) (radiator-thermostat) 

• Pipe (6) (filler-tank) 

• Pipe (7) (tank overflow) 

• Filler cap (8) 

• Reservoir tank (9) 

Cracks/Damage -* Replace. 

See the section "COOLING SYSTEM* 
chapter 5. 



in 



3-31 



3-32 



FRONT BRAKE ADJUSTMENT 




INSP 
ADJ 


Wlk 



CHASSIS 

FRONT BRAKE ADJUSTMENT 

1. Check; 

• Free play at the end of brake lever (A) 
Out of specification -4 Adjust. 




Free play {at the end of lever): 
10 - 15 mm 



2. Adjust: 

• Brake lever free play 



Y********** 



* t * 



ft*********** 



Adjustment: 

• Extract the adjuster lock spring. 

• Turn the adjuster (1) either way to obtain the 
correct free play. 



Screwing 


Free play diminishes 


Unscrewing 


Free play increases 



Reassemble properly the adjuster safety spring. 



CAUTION: 



Proper lever free play is essential to avoid 
undue brake pad friction. 



A WARNING 



A soft or spong feeling in the brake lever can 
indicate the presence of a!r in the brake system. 
This air must be removed by bleeding the brake 
system before the motorcycle is operated. Air 
in the system will cause greatly diminished 
braking capability and can result in loss of 
control and an accident. Inspect and bleed the 
system if necessary. 




REAR BRAKE ADJUSTMENT 



INSP 
ADJ 


09 




REAR BRAKE ADJUSTMENT 

1. Check: 

• Free play of brake pedal (A) 
Out of specification -> Adjust. 




^ 



Brake pedal free play (A): 
0.5 - 1 mm 



2. Adjust: 

* Brake pedal free play 



Adjustment: 

• Loose the eccentric screw (2). 

• Turn the eccentric either way to obtain the 
correct free play. 

• Tighten the eccentric screw. 

• Recheck brake pedal free play. 



t * * ± 



NOTE: 



***** ft 



m * # * 



A * * * * 



Factory configured brake pedal position. 

To change pedal position: 

1 . Loose: 

• Adjuster lock nut (1) 

2. Turn: 

• Adjuster pivot (to the right position) 

3. Tighten: 

• Adjuster fock nut 

4. Adjust: 

• Brake pedal free play 



CAUTION: 



"SIB 



Proper pedal free play is essential to avoid 
undue brake pad friction. 



A WARNING 



A soft or spong feeling in the brake pedal can 
indicate the presence of air in the brake system. 
This air must be removed by bleeding the brake 
system before the motorcycle is operated. Air 
in the system will cause greatly diminished 
braking capability and can result In loss of 
control and an accident Inspect and bleed the 
system $f necessary. 



3-33 



3-34 



A 




BRAKE FLUID LEVEL CHECK 



BRAKE FLUID LEVEL CHECK 



NOTE; 



INSP 
ADJ 


pa 




When checking the level of the ffuid make certain that 
the position of the motorcycle is level and perfectly 
upright and, turning the handle bar, that the top of 
the front tank cover is in a horizontal position. 



1. Check: 

• Level of brake fluid 

If the level is beiow the minimum (2) 
up to the maximum level (3). 



Top 



•ti 



Recommended brake fluid: 
DOT No. 4 



[A] 


Front brake 


[B] 


Rear brake 


(1) 


Brake fluid tank 


(2) 


Minimum ievel 


(3) 


Maximum level 


CAUTION: 



The brake fluid may corrode painted surfaces 
and plastic parts. Always clean up spilled fluid 
immediately. 




BRAKE PAD WEAR INSPECTION/ 
BRAKE HOSING INSPECTION 



INSP 
ADJ 


W3k 




BRAKE PAD WEAR INSPECTION 

1 . Operate the brake lever or brake pedal. 

2. Check: 

• Thickness of frictional material 

Out of specification -» Replace. 




Wear limit (A): 
Front: 0.8 mm 

Rear; 0.8 mm 




For brake pad replacement, see the section 
"BRAKE PAD REPLACEMENT in chapter 7. 

[A] Front brake 
[Bj Rear brake 



BRAKE HOSING INSPECTION 

1 . Inspect: 

• Brake hosing 

Cracks/Damage -» Replace. 
To replace hosing, see the section "FRONT 
AND REAR BRAKE" in chapter 7°. 



A WARNING 



Use only brake fluid in conformity with pre- 
scribed standards, otherwise the rubber gas- 
kets risk deteriorating, causing fluid leakage 
and poor brake performance. 
Always use the same brand of fluid. The 
mixing of fluids could provoke a chemical 
reaction which would, in turn, result in poor 
brake performance. 

When adding fluid be sure that no water or 
foreign bodies enter the fluid tank. Water 
would lower the boiling point, generating 
vapour bubbles during braking. 



3-35 



3-36 



BRAKE CIRCUIT BLEEDING 



INSP 
ADJ 


E*9 



BRAKE CIRCUIT BLEEDING 



A WARNING 



If the brake lever or brake pedal has a soft or 
slack feel, this means that there is air in the 
brake system. It should be bled away before 
using the cycle. Air in the system seriously 
affects the effectiveness of braking and may 
cause loss of control of the motorcycle. 
In all cases, bleed the brake system if: 

• The system has been disassembled. 

• A brake hose has been loosened or removed. 

• The brake fluid in the tank is at a very iow 
level. 

• Brake operation is faulty- 
Air bleeding procedures: 

a. Top up the level of the fluid in !he tank to 
maximum. 

b. Install the diaphragm. Be carefuf not to spill fluid 
or let it overflow from the tank. 

c. Connect a clear plastic hose to the caliper bleeder 
screw. 

d. Place the other end of the hose in a container. 

e. Slowly pull the brake lever or press the brake 
pedal several times. 

f. Pull the brake lever right in or press the pedal 
right down and hold in position. 

g. Loosen the bleeder screw and allow the lever or 
pedal to travel slowly towards its limit. 

h. Tighten the bleeder screw when the lever or 
pedal limit has been reached, then release the 
lever or pedal. 




\ 



Bleeder screw: 
6 Nm (0.6 mkg) 



i. Repeat operations (e) to (h) until all the air 
bubbles have disappeared from the clear plastic 
hose. 

NOTE: 

If bleeing proves difficult, it may be necessary to 
allow the brake fluid system to stabilise lor a few 
hours. Repeat the bleeding procedure when the 
tiny bubbles in the system have disappeared. 

Top up fluid to the maximum level. 




DRIVE CHAIN TIGHTNESS INSPECTION AND 

ADJUSTMENT 



INSP 
ADJ 


pa 





DRIVE CHAIN TIGHTNESS INSPECTION AND 
ADJUSTMENT 

Inspecting tightness: 

NOTE: 

Before checking and/or adjusting the chain, rotate 
the rear wheel through several revolutions and 
check the tightness several times to find the point 
on the wheel where chain tightness is highest. 
Check and/oradjust chain tightness with rear wheel 
in this "light chain" position. 



1. Check: 

• Drive chain slack (A) 

Out of specification -> Adjust. 




^ 



Drive chain slack (A): 
25 - 40 mm 



NOTE: 

To check chain tightness, the motorcycle must 
stand in an upright position with its two wheels 
touching the ground and no one sitting on it. Check 
tightness in the position shown in the figure. 

2. Adjust: 

• Drive chain tightness 

Tightness adjustment: 

CAUTION; 

An unduly tight chain will overload and damage 
the engine and drive parts. Be careful therefore 
to keep chain tightness within the limits 
specified. 

• Loosen the rear wheel axle nut {1). 

• Loosen the lock nuts (2) on either side of the 
chain stretchers. 

# Turn both chain stretchers (R and L) (3) by the 
same amount to obtain the required tightness. 

♦ After adjusting, screw the rear wheel axle nut to 
the specified torque. 




Real wheel axle nut: 
80 Nm (8,0 mkg) 



NOTE: _ — — 

Turn the two chain stretchers (3) in exactly the 
same way to keep the wheel properly centred. 



3-37 



3-38 



DRIVE CHAIN LUBRICATION 



INSP 
ADJ 


ra 




FRONT FORK INSPECTION AND ADJUSTMENT 



r*=*\ 




DRIVE CHAIN LUBRICATION 

The chain consists of many small parts which 
operate one over another. If it is not properly 
maintained, it will wear quickly. It is thus necessary 
to carry out regular maintenance work on the chain, 
especially if the motorcycle is often driven over 
dusty surfaces. The motorcycle is fitted with a chain 
with small O-rings between the plates. Cleaning 
with steam, pressurised products and some sol- 
vents may damage these rings. Clean the chain 
with kerosene only. After cleaning, dry the chain 
with compressed air f then lubricate well with SAE 
30W/50 engine oil or a special lubricant for chains 
with O-rings. He^er use other lubricants since they 
may contain solvents harmful to the O-rings. 




Recommended lubricant: 
SAE 30W/50 engine oil 



(1) O-rings 



INSP 
ADJ 


pa 





FRONT FORK INSPECTION AND 
ADJUSTMENT 



A WARNING 



When inspecting the front fork, hold the motor- 
cycle firmly to prevent it falling over. 

Visual inspection: 

1. Check: 

• Inner tubes 
Scratches/Dents/Damage -» Replace. 

• Oil seals 

Undue oil leakage -> Replace. 

Operating inspection: 

1. Check: 

• Proper functioning 

With the motorcycle in a level upright posi- 
tion and with your hands on the handle bar, 
operate the front brake. Then compress 
and release the front fork several times. 
Irregular/jerky functioning •*» Repair. 

Adjustment: 

Fork damper adjustable both in extension (right 
fork adjustment) and compression (left fork 

adjustment). 

CAUTION: 

Do not force the adjusting screw beyond the 
minimum and maximum limits. 

Adjustment of extension damping effect 
On the cap of right fork is a screw (1 ) which adjusts 
damping effect during front fork extension. 
Turning the screw clockwise (A) the damping effect 
increases, anticlockwise (B) it decreases. 



ADJUSTMENT FIELD 


Maximum I Minimum 


Screw completely 
tightened in clockwise 
direction (A) 


Screw turned 24 
clicks in anticlockwise 
direction (B) 


Standard adjustment; 13 clicks from maximum 



3-39 



3-40 



FRONT FORK INSPECTION AND ADJUSTMENT/ 
SHOCK ABSORBER INSPECTION AND ADJUSTMENT 



INSP 
ADJ 


09 




Compression damping effect adjustment 
On the cap of left stem is a screw (2) which serves 
to adjust the compression damping effect. 
To increase the damping effect, turn the adjuster 
clockwise (A), to reduce it turn the adjuster anti- 
clockwise (B). 



ADJUSTMENT FIELD 



Maximum 
Fully turned in position 

Standard adjustment 

13 clicks from maximum 

Minimum 

24 clicks anticlockwise (B) from maximum 



D-3 



SHOCK ABSORBER INSPECTION AND ADJUSTMENT 



INSP 
ADJ 


ra 




NOTE: 

The shock absorber spring preload may be ad- 
justed according to the drivers preferences, to the 
weights being carried and to road conditions. 



A WARNING 



Hold the motorcycle firmly in place to prevent it 
failing over. 

Spring preload adjustment 

Adjust the spring preload as follows: 

• Loosen the lock nut (1 ). 

• To increase the preload, turn the adjuster (2) 
clockwise. To reduce it, turn anticlockwise. 

• The spring preload changes by 1 mm per turn of 
the adjuster. 



NOTE: 

For adjustment purposes, use the special wrench 
provided with the motorcycle. 

• After adjusting, screw lock nut (2) to the adjuster 
(1) and tighten to prescribed torque. 




Shock absorber lock nut: 
42 Nm (4.2 m kg) 



CAUTION: 



SHOCK ABSORBER INSPECTION AND 
ADJUSTMENT 



A WARNING 



This shock absorber contains highly com- 
pressed nitrogen gas. 

Read these warnings carefully before handling 
the shock absorber.The manufacturer declines 
all responsibility for damage or wounds due to 
improper handling. 

• Donottamperwfth ortrytoopen the cylinder. 
This may cause damage or wounds to the 
operator. 

• Do not expose the shock absorber to naked 
flames or any other heat sources: excess gas 
pressure might cause it to explode. 

• Do not deform or damage the cylinder in any 
way. Damage to the cylinder might jeopard- 
ise the damping effect. 



Never attempt to turn the adjuster beyond the 
maximum or minimum setting. 



Spring length with preload 


Standard length 


166 mm 


Minimum length 


161 mm 


Maximum length 


170 mm 



3-41 



3-42 



SHOCK ABSORBER INSPECTION AND ADJUSTMENT/ 

STEERING INSPECTION 



INSP 
ADJ 


pa 




Extension damping effect adjustment 

To increase the extension clamping effect, turn the 
setting (3) at the base of the shock absorber clock- 
wise (A). To reduce it turn anticlockwise (B). 

Adjustment field 

Maximum effect: adjuster fully turned in. 
Standard adjustment: adjuster turned 1 clicks out 

from maximum. 




STEERING INSPECTION 



INSP 
ADJ 


1*9 




Adjustment: 

• Loosen steering column nut (1) and upper fork 

plate screws (2). 

• Tighten ring nut (3) with the special wrench. 



&£? Ring nut wrench: 
4r P/N.YU-01268 

P/N. 90890-01268 




Ring nut (initial tightening): 
38 Nm {3.8 mkg) 



Loosen the ring nut one turn. 

Retighten the ring nut using the special 

wrench. 



A WARNING 



Do not tighten the ring nut excessively. 




Ring nut (final tightening): 
3 Nm (0.3 mkg} 



Tighten the steering column nut and (he 
front fork plate screws. 




4? **& 



s 









»»&: %3&m) 




STEERING INSPECTION 



A WARNING 



Hold the motorcycle firmly in place to prevent it 
fafling over. 

1 . Raise the front wheel and place a support 
under the engine. 

2. Check: 

• Steering bearings 

Grasp the bottoms ot the front fork stems 

and rock back and forward. 

free play -» Adjust steering bearing. 

3. Adjust: 

• Steering bearing 




Nut (steering column): 
110 Nm (11.0 mkg) 

Screws (front fork plate): 
23 Nm (2.3 mkg) 



3-43 



3-44 



FRONT: 



REAR: 




TYRE INSPECTION 



INSP 
ADJ 


09 



TYRE INSPECTION 



A WARNING 



Make 


Measurement 


Type 


MiCHELIN 


11 0/70 ZR 17 


TX15 


DUNLOP 


110/70 ZR 17 


TL 



Make 


Measurement 


Type 


MICHELIN 


150/60 ZR 17 


TX25 


DUNLOP 


150/60 ZR 17 


TL 



Tyre pressure must be checked when the 
tyres are at ambient temperature. Pressure 
must be adjusted according to the total weight 
of luggage, driver, passenger and accesso- 
ries (fairings, bags, if approved for this model) 
and speed of the motorcycle. 
A list of tyres approved for this model follow- 
ing severe testing by Beigarda S.p.A is pro- 
vided. There can be no guarantee of safe 
roadholding if a combination of tyres differ- 
ent from those indicated is used. 
Front and rear tyres must have the same 
design and be of the same make. 
The use of valves and valve stems other than 
those Indicated might cause the loss of tyre 
pressure at high speeds. Use only original or 
compatible spare parts. 
Replace the valve cap securely to prevent 
losses of tyre pressure at high speed. 



1. Check; 

• Tyre pressure 

Out of specification -» Adjust. 



INFLATING PRESSURES m bar (psi) 


With driver only 


Front 


Rear 


2(28) 


2.2 (32) 


With driver 
and passenger 


2.2 (32) 


2.5 (37) 



2. Adjust: 

• Air pressure 




TYRE INSPECTION 




m it * # 



* * * * * 



Adjustment: 

• Remove the valve cap- 



Use an air pump or 
compressed air pis- 
tol 


Increase air 
pressure 


Eliminate air by 
pressing valve tube 
stem 


Afr pressure 

diminishes 



Install valve caps securely. 



3. Inspect; 

♦ Tyre surface 

Wear/Damage -» Replace. 




m 



Minimum track thickness 
(front and rear): 
1.0 mm 



(1) Track thickness 

(2) Side 

(3) Wear indicators 



A WARNING 



► The use of worn tyres reduces stability and 
may cause a loss of control, 

• The tyres mounted on the cycle are "tube- 
less": ie, without air chambers. In order to 
avoid compromising the safety of the cycle, 
never mount an air chamber, even in the 
event of repairs to the tyre. 

4, Tighten; 

♦ Valve stem lock nut 




Valve stem lock nut: 
1.5 Nm {0.15 mkg) 



A WARNING 



After assembling the new tyres, drive slowly to 
allow them to adapt well to the rim and ensure 
maximum grip. 



3-45 



3-46 



WHEEL INSPECTION/ 
CABLE INSPECTION AND LUBRICATION 



INSP 
ADJ 


r 



WHEEL INSPECTION 

1. Inspect: 

• Wheels 

Damage/Deformation/Fissures 

place. 



Re- 




LEVER AND PEDAL LUBRICATION/SIDE STAND/SWING ARM/ 

HEADLIGHT: LAMP REPLACEMENT AND SETTING 



LEVER AND PEDAL LUBRICATION 

Lubricate all lever and pedal pins. 



INSP 
ADJ 


em 




Recommended lubricant: 
SAE10W30 engine oil 



NOTE: _ _ 

Always balance the wheel after the replacement or 

reassembly of a tyre. 



A WARNING 



Never try to repair a wheel in any way. If a wheel 
is deformed or cracked, it must be replaced. 

Bearing inspection 

Check the front and rear wheel bearing periodically 
to make sure that they do not have free play in the 
hub and that the wheel turns smoothly without 
sticking. Wheel bearings must always be checked 
in accordance with the maintenance table. 




SIDE STAND LUBRICATION 

Lubricate the side stand and articulations. 




Recommended lubricant: 
SAE10W30 engine oil 



SWING ARM LUBRICATION 

Lubricate the swing and connection arm pivots. 




CABLE INSPECTION AND LUBRICATION 



A WARNING 



If the cable sheath is damaged, corrosion might 
ensue or the cable might not run freely. To 
avoid such drawbacks, replaced damaged 
cables as quickly as possible. 

1 . Inspect: 

• Cable sheath 

Damaged -> Replace. 

2. Check: 

♦ Cable functioning 

Does not run freely -» Lubricate. 




Recommended lubricant: 
SAE10W30 engine oil 



NOTE: 

Hold the cable vertical and apply a few drops of 
lubricant 





ELECTRICALS 

HEADLIGHT: LAMP REPLACEMENT AND 
SETTING 

Replacing the headlight bulbs 

1 . Approach the light from behind the front cowl- 
ing: 

(1) Low beam bulb 

(2) High beam bulb 

2. Remove: 

• Rubber protection 

3. Detach: 

• Connectors 

• Fastener small spring edges (3) 

4. Extract: 

• Lamp (4) 



3-47 



3-48 



HEADLIGHT: LAMP REPLACEMENT AND SETTING 



INSP 
ADJ 


pa 




FUSE INSPECTION AND REPLACEMENT 



INSP 
ADJ 


pa 





5. install: 

♦ New lamp 

• Lamp fastening small spring 

• Lamp connector 

♦ Rubber protection 



A WARNING 



Do not touch the lamp when on and keep all 
inflammable products well away. 




CAUTION: 



Do not touch the glass part of the lamp with the 
fingers and be careful not to soil it. If it is soiled, 
clean thoroughly with a cloth soaked in alcohol 
before reassembling. 

Front parking light lamp replacement 

1. Remove: 

• Lamp holder (1) (pressure fitted) 

• Lamp (2) (pressure fitted) 

2. Install: 

• New lamp (pressure fitted) 

• Lamp holder (pressure fitted) 




B 




Vertical setting of the headlight beam 

1 . Approac the setting screw (3) in the rear part 

of the headlight 

2. Screw or unscrew: 

• Adjusting screw (3) 



Screw 


Increase the headlight beam 


[ Unscrew 


Decrease the headlight beam 



FUSE INSPECTION AND REPLACEMENT 



1. 



Remove: 

• Seat 

• Fuse box (1 - main, 2 - fan motor) 

• Fuse (from fuse box) 



2. 



Inspect: 
• Fuse 

(A) Intact fuse 

(B) Broken off fuse 



3. Replace: 
• Broken fuse 



Replacement: 

• Disconnect the main switch (OFF position), 

• Replace the fuse with a new one with suitable 

amperage- 



Prescribed fuses: 

{1) Main fuse: 20A 

(2) Electric fan motor fuse: 7.5A 



Turn on main switch {ON position). 

Operate the various switches, turning on a 

electric devices to check that they are working. 

If the fuse burns out again, check the circuit in 
question. 



A WARNING 



Do not use fuses with an amperage higher than 
that prescribed. Such fuses might cause dam- 
age to the motorcycle and even fire. 



4, Install: 

• Fuse box 

• Seat 



3-49 



3-50 




BATTERY INSPECTION 



INSP 
ADJ 


pa 



BATTERY INSPECTION 



NOTE: 

The battery mounted on the motorcycle is of the 
maintenance-free sealed type (MF). It is thus im- 
possible to measure electrolyte density to check 
the battery charge. The battery charge is checked 
by measuring the voltage at the battery terminals. 



CAUTION; 



Charging method 

• The battery is of the sealed (MF) type. Do not 
remove caps during charging. If the caps are 
removed, the balance of the battery is not main- 
tained and its performance progressively dimin- 
ishes. 

• Never add water, not even distilled water. Other- 
wise, the chemical reactions in the battery will 
not take place normally, making regular 
functioning impossible. 

• The charging time, current and voltage of a MF 
battery are different from those of a normal 
battery. 

The MF battery must be charged as described in 
the section "Charging method". If the battery 
were overcharged, the level of the electrolyte 
would drop considerably. Pay careful attention 
therefore while charging the battery. 

• Avoid using electrolyte other than that specified. 
The specific density of the electrolyte in the 
battery is 1.32 at 20°C (the specific density of 
electrolyte for normal batteries is 1.28). If an 
electrolyte of specific density lower than 1.32 
were used, the sulphuric acid would diminish, 
thus reducing the performance of the battery. If 
an electrolyte with a specific density of 1.32 or 
over were used, the battery plates would be 
corroded and the battery would last less. 




BATTERY INSPECTION 



INSP 
ADJ 


WA 




A WARNING 



The electrolyte in the battery is dangerous: it 
contains sulphuric acid and is thus poisonous 
and extremely corrosive. 
Always observe the following prevention meas- 
ures: 

• Avoid physical contact with the electrolyte 
as it may cause serious burns or permanent 
damage to the eyes. 

• Wear eye protections when handling or work- 
ing with batteries, 

(EXTERNAL) ANTIDOTO: 

• SKIN - Rinse with water. 

• EYES - Rinse with water for 15 minutes and 
call a doctor immediately. 

(INTERNAL) ANTIDOTO: 

• Drink copious amounts of water or milk fol- 
lowed by milk of magnesia, scrambled eggs 
or vegetable oil. 

Call a doctor immediately. 

Batteries generate explosive hydrogen gas: ob- 
serve the following prevention measures: 

• Charge the battery in a well-aired space. 

• Do not allow fire, sparks or flames (eg weld- 
ing equipment, lit cigarettes etc) near to the 
batteries. 

« DO NOT SMOKE when charging or handling 
batteries. 

KEEP THE BATTERY AND ELECTROLYTE 
WELL OUT OF THE REACH OF CHILDREN. 



CAUTION: 




When you are removing battery from chassis, 
first disconnect H pole, then (+) pole. When 
you are mounting battery onto chassis, first 
connect (+) pole, then (-) pole. 



1. Remove: 

* Seat 

• Elastic belt fastening battery (1) 



NOTE: — _ : 

You can install battery easily from front side of its 
seat, under tank, by removing two clamping screws 
of tank and lifting it without discoupling fuel hoses. 



3-51 



3-52 




£.','«. 


Relationship between open-circuit 




"*^^UUTTr>w vonage and charging nme. 


a 


■ ^^%}w 


? 

s 

C± pi % - 

o 


^\v 


1 


^%^ 




Charging lime* 


* This vanes depending on the temperaiure, the state of charge in 


battery plates and the electrolyte level. 



** 

U 

'!■■ 

o 

111 










Roomt 
0*C 


emperalure 

;^*o°c 






r^jT^^^ 














i 










I 

1 

1 




■w J» >*, Jf> v 

Charging conations of the battery (%) 



BATTERY INSPECTION 

2. Disconnect: 

• Battery cables 

CAUTION: 



INSP 
ADJ 


pa 




BATTERY INSPECTION 



Disconnect first the negative cable, then the 
positive cable. 

3. Remove: 

• The battery 

4. Check: 

• The conditions of the battery 

Battery condition check stages: 

• Connect the pocket tester to the battery termi- 
nals. 

Tester (+) wire -» Battery terminal (+) 
Tester (-) wire -> Battery terminal (-) 

NOTE: t 

The charging timefora partially or totally MF battery 
may be checked by measuring the open circuit 
voltage (the voltage measured with the positive 
terminal disconnected). 



Open-circuit 

voltage 


Charging time 


12.8V or more 


Charging unnecessary 


12.7V -11.5V 


5- 10 hours 


Fewer than 11,5V 


15 -20 hours 



Battery charging time according to charging con- 
ditions are shown in the figure. 



5. MF battery charging method. 



CAUTION; 



• If jt is impossible to obtain the envisaged 
charge current voltage, charge the battery 
according to the instructions In the section 
"Charging with a constant voltage battery 
charger". 



INSP 
ADJ 


0*9 



1" 


Charging time 


Room temperatufe 
25" 














L 




—_.-_- 


■ - 


. . . 






_„. — 






^™ ^^ * » 










, _, 


. - J 
1 

1 


^^^^^^^^^^B 


j ' 




1 \ 

u ; - 










j 










1 

I 


i 








»w 


w "i 


j » JL >W -)V H 

1 fr Checfr tf>e open-cireuil voltage 



When charging the battery, remove it from 
the motorcycle. If it is necessary to recharge 
the battery on the motorcycle, be sure to 
disconnect the negative terminal. 
Never remove the battery caps. 
Make sure that the battery charger pincers 
are firmly in contact with the terminals and 
are not in short circuit An oxidised plncer 
may generate heat on the surface of the con- 
tact. A pincer with a weak spring may cause 
sparks. 

Before removing the pincers from the battery 
terminals, turn off the battery charger. 
Voltage readings are shown in the diagram. 
The open circuit voltage stabilises about 30 
minutes after the cycle has been completed. 
Thus, to check the conditions of the battery, 
measure the open circuit voltage 30 minutes 
after the charging has been completed: 



3-53 



3-54 



BATTERY INSPECTION 



INSP 
ADJ 


pa 




BATTERY INSPECTION 



Method for charging with a variable voltage battery charger 



Battery charger Amperometer 




Measure the open circuit voltage 
before charging. 



T 




Connect the battery charger and 
amperometer to the battery and 
start to charge. 



i 



Check that the current is higher 
than the standard charging cur- 
rent indicated on the battery. 



NOTE: 

The current must be measured 30 
minutes after stopping the cycle. 

NOTE: 

Set the charge voltage at 16- 17V. 
(If the setting is lower, the charge 
will be insufficient. If the setting is 
too high, the battery is overloaded). 

NOT 



Method for charging with a constant voltage battery charger 



INSP 
ADJ 


ra 



Measure the open circuit voltage 
before charging. 



T 



NOTE: 

The current must be measured 30 
minutes after stopping the cycle. 



Connect the battery charger and 
amperometer to the battery and 
start to charge. 



i 



YES 



Turning the charge voltage regu- 
lation control, set the charging 
voltage to 20 —25V. 



Check that the current is higher 
than the standard charging cur- 
rent indicated on the battery. 



NOT 



Adjust the voltage so that the cur- 
rent is at the standard charge level 



1A or less 



I 



Check the amperage for 3-5 min- 
utes to see if the standard charge 
current is reached. 



1A or more 



If the current is higher than 1A, 
regulate the voltage to 16 -17V 
and continue to charge. 



Set the timer to the charging time 
suitable for the open circuit volt- 
age. 



After 5 minutes, regulate the 
voltage to 1 6 * 17V and con- 
tinue to charge. 



Charge the battery until the charg- 
ing voltage is 1 6V or more. 



NOT 



NOTE: 

Set the charging time at 20 hours 
(maximum). 



This type of battery chargercannot recharge 
an MF battery, 

A variable vottage or constant current bat- 
tery charger is recommended. 



If the current does not ex- 
ceed standard charge cur- 
rent after 5 minutes, replace 

the battery. 



Measure the open circuit battery vottage 

after leaving the battery unused for over 30 

minutes. 

12.8V or more - Charging complete. 

12.7V or less - Recharging necessary. 

Under 12.0V - Replace battery. 



Battery charger 



Voltmeter 



Amperometer 



If charging takes more than 5 hours, it is advisable to check the charge current after 
5 hours. If there are changes in amperage, regulate the voltage to obtain Ihe standard 
charge current. 



Measure the open circuit battery voltage after leaving the battery unused 

for over 30 minutes. 

12.8V or more - Charging complete. 

12.7V or less - Recharging necessary. 

Under 12.0V - Replace battery. 




3-55 



3-56 



BATTERY INSPECTION 





Method for charging with a constant current battery charger (exclusively for MF batteries) 



NOTE: ™ 

The current must be measured 30 
minutes after stopping the cycle- 



Measure the open circuit voltage 
before charging. 



I 



Conned the battery charger and 
amperemeter to the battery and 
start to charge. 



BATTERY INSPECTION 



INSP 
ADJ 


ra 



6. inspect: 

• Battery terminals 

Dirty poles -» Clean with steel brush- 
Uncertain connections -*• Tighten termi- 
nals. 

NOTE: __. 

After cleaning the poles, grease them slightly. 



YES 



After an hour's charging, check 
that the nominal charging current 
of the battery charger is flowing by 
checking the arnperometer. 



NOT 



Since the charging current is constant, the 
charging time varies according to the ca- 
pacity of the battery. Set the charging time 
by following the instructions specified for 
the battery charger. 



If the nominal current fails to flow, replace the 
battery. 



Measure the open circuit battery voltage 
after leaving the battery unused for over 30 
minutes. 

12.8V or more - Charging complete. 
12.7V or less - Recharging necessary. 
Under 12.0V - Replace battery. 



Battery charger 

o 



Arnperometer 




7. Install: 
♦ Battery 



NOTE: _____ _____ 

To introduce battery under the seat, put battery in 
horizontal position and introduce it into chassis 
from short side. After bringing it near seat, turn it 90° 
horizontally, set it to vertical position and low it into 
its seat with poles backward. You can install battery 
easily from front side of its seat, under tank, by 
removing two clamping screws of tank and lifting it 
without discoupling fuel hoses. 

8. Connect; 

• Battery cables 

CAUTION: 

Connect first the positive cable, then the nega- 
tive cable. 

9. Install: 

• Elastic beft fastening battery 

• Seat 



3-57 



3-58 



CHAPTER 4° 
ENGINE OVERHAUL 





ENG 


%m 



ENGINE REMOVAL D-14 

COWLING, SEAT AND FUEL TANK D-14 

ENGINE OIL D-14 

COOLING SYSTEM D-14 

BATTERY CABLES D-14 

RADIATOR D-14 

EXHAUST PIPE D-15 

AIR CLEANER CASE AND CARBURETOR D-15 

CLUTCH CABLE D-15 

DRIVE CHAIN D-15 

ENGINE DETACHMENT D-16 

ENGINE DISASSEMBLY E-1 

STARTER MOTOR AND HOSES E-1 

CYLINDER HEAD, CYLINDER AND PISTON E-1 

ROTOR AND STARTER DRIVERS E-3 

OIL FILTER AND WATER PUMP E-4 

CLUTCH AND BALANCER GEAR E-5 

SHIFT LEVER AND OIL PUMP E-6 

CRANKCASE (RIGHT) E-7 

OIL STRAINER E-8 

BALANCER, TRANSMISSION AND SHIFTER E-8 

CRANKSHAFT E-9 

ROCKER ARM E-9 

VALVES E-10 

INSPECTION AND REPAIR E-1 1 

CYLINDER HEAD E-1 1 

VALVES AND VALVE GUIDES E-1 1 

VALVE HOUSING E-12 

VALVE SPRING E-14 

CAMSHAFT E-14 

ROCKER ARMS AND ROCKER ARM SHAFT E-15 

CAMSHAFT CHAIN, SPROCKET AND CHAIN GUIDE E-15 

CAMSHAFT CHAIN GUIDE E-16 

CYLINDER AND PISTON E-16 

PISTON RiNGS F-1 

PISTON PIN F-2 

CRANKSHAFT F-2 

BALANCER DRIVE GEAR AND BALANCER GEAR F-3 

ELECTRIC STARTER DRIVE F-3 

PRIMARY DRIVE F-3 



CLUTCH F-3 

TRANSMISSION AND GEARBOX F-5 

OIL PUMP, WATER PUMP AND STRAINER .' F-6 

OIL DELIVERY PIPES F-6 

CRANKCASE F-6 

BEARINGS AND OIL SEALS F-6 

CIRCLIP AND WASHER F-6 

ENGINE ASSEMBLY AND SETTING F-7 

VALVES AND ROCKER ARMS F-7 

VALVES F-7 

ROCKER ARMS F-8 

CRANKSHAFT F-9 

CRANKSHAFT AND BALANCER SHAFT F-10 

TRANSMISSION F-10 

BALANCER, TRANSMISSION AND SHIFTER F-1 1 

OIL STRAINER (EXPLODED VIEW) F-12 

CRANKCASE (EXPLODED VIEW) F-12 

SHIFT LEVER AND OIL PUMP F-13 

CRANKCASE (ASSEMBLING) F-13 

OIL STRAINER (ASSEMBLING) F-13 

SHIFT LEVER AND OIL PUMP F-14 

BALANCER SHAFT GEAR F-15 

CLUTCH F-15 

CLUTCH AND BALANCER GEAR F-16 

OIL FILTER AND WATER PUMP G-2 

STARTER GEARS G-3 

CYLINDER G-4 

CYLINDER HEAD G-5 

CAMSHAFT AND CAMSHAFT CHAIN G-5 

CYLINDER HEAD, CYLINDER AND PISTON G-6 

PIPES AND HOSES G-9 

ENGINE REASSEMBLY G-10 



ENGINE REMOVAL 



ENG 


%m 




ENGINE OVERHAUL 



ENGINE REMOVAL 



NOTE: 



It is not necessary to detach the engine from the 
chassis to remove the following parts; 

• Cylinder head 

• Cylinder 

• Piston/Piston rings 

• Clutch 

• Water pump 

• Oil pump 

• Alternator 



A WARNING 



Support the motorcycle securely to prevent it 
falling over. 

COWLING, SEAT AND FUEL TANK 

1. Remove: 

• Side panels (L and R) 

• Seat 

• Fuel tank 

See the section "COWLING" and "SEAT, 
FUEL TANK AND REAR COWLING" in 
chapter 3. 

ENGINE OIL 

1. Drain: 

• Engine oil 

See the section "ENGINE OIL REPLACE- 
MENT* in chapter 3. 

COOLING CIRCUIT 

1 . Drain: 

• Cooling circuit 

See the section "CHANGING THE 
COOLANT" in chapter 3. 

BATTERY CABLES 

1. Disconnect: 

• Battery cables 

CAUTION: _^^ 

Disconnect first the negative cable (-), then the 

positive cable (+). 

2. Remove: 

• Battery 



ENGINE REMOVAL 



ENG 


\w 



RADIATOR 




JOB INSTRUCTION CHART 



Order 


Job name/Part name 


Q.ty 


Remarks 




Removal of radiator 




Remove the parts in the order. 


1 


Clamp 






2 


Clamp 






3 


Screw 






4 


Screw 






5 


Screw 






6 


Radiator (disconnect electrical 








connector) 




Reverse the removal procedure for installa- 








tion. 



4-1 



4-2 



ENGINE REMOVAL 





EXHAUST PIPE 




JOB INSTRUCTION CHART 



Order 



1 
2 

3 
4 



Job name/Part name 



Q.ty 



Removal of exhaust pipe 

Nut 

Screw 
Screw 
Exhaust pipe (assembly) 



4 
1 
1 

1 



Remarks 



Remove the parts in the order. 



Reverse the removal procedure for in- 
stallation. 



ENGINE REMOVAL 



ENG 


%B 







■mmm 



£ 



/V 




ir«B»ftnK 





AIR FILTER CASE AND CARBURETOR 

1 . Loosen; 

• Carburetor manifold clamps {1 ) 

2. Remove; 

• Air filter case (2) 

• Air panef (3) 

3. Disconnect; 

• Engine idle speed control knob bracket (4) 

• Starter control knob bracket (5) 

4. Loosen: 

• Carburetor joint clamps (6) 

5. Remove; 

• Carburetors (7) 



NOTE: „ 

Cover the carburetor with a rag to prevent dirt or 
foreign bodies entering. 



CLUTCH CABLE 

1 . Loosen: 

• Nut(1) 

2. Disconnect: 

♦ Clutch cable (2) 

(from lever and bracket) 



DRIVE CHAIN 



Loosen: 

• Rear wheel axle nut (1) 

• Lock nut (2) of the chain stretchers 

• Chain stretcher screws (3) 
Remove: 

• Sprocket cover 
Straighten; 

• Lock washer tab 



3. 



4. 



Remove: 

• Nut(1) 

• Lock washer (2) 

• Sprocket (3) 



NOTE: __™____^^ 

Loosen the sprocket nut ( 1 ) while applying the rear 
brake. 



4-3 



4-4 



ENGINE REMOVAL 





ENGINE REMOVAL 



ENGINE DETACHMENT 




ENG 


\m 



JOB INSTRUCTION CHART 



Order 


Job name/Part name 


Q.ty 


Remarks 




Detachment of engine from frame 




Remove the parts in the order. 


1 


Screw 


2 




2 


Bracket 






3 


Crankcase ventilation hose 






4 


Screw (oil recovery hose) 






5 


Screw (oil delivery hose) 






6 


Oil tank 






7 


Spark plug cable 






8 


Wire harness connector 


3 




9 


Starter plus leadwire 






10 


Shift pedal 






11 


Bolt (engine mounting} 






12 


Screw (engine mounting) 






13 


Screw (engine upper mounting) 


2 




14 


Axle (engine front mounting) 






15 


Engine 






16 


Bolt (engine upper mounting stay) 






17 


Engine upper mounting stay 






18 


Bolt (engine front mounting stay) 


2 




19 


Engine front mounting stay 


1 


Reverse the removal procedure for installa- 
tion. 



4-5 



4-6 





ENGINE DISASSEMBLY 





ENGINE DISASSEMBLY 

STARTER MOTOR AND HOSES 

V. Remove: 
• OH pipe (1) 



2. Remove: 
• Oil pipe (1) 



ENGINE DISASSEMBLY 



ENG 


%m 



CYLINDER HEAD, CYLINDER AND PISTON 



NOTE; 



With the engine mounted, the cylinder head cover, 
camshaft and cylinder head can be maintained by 
removing the following parts. 

• Seat 

• Fuel tank 

• Cowling 

• Radiator 

• Exhaust pipe 

• Ignition coil 

• Air filter case 

• Air panel 

• Carburetor 




3. Remove: 

• Starter motor (1 




1. Remove: 

♦ Sparkplug {1) 







4. Remove: 

• Oil hose (1) 

• Breather hose (3) (crankcase 




2. Remove: 

• Intake manifolds (1) 




5. Remove: 

• Coolant hose (1 




3. Remove: 
• CapO) 



4-7 



4-8 





ENGINE DISASSEMBLY 





4. Remove: 

• Timing plug (1 

• Plug (center) (2) 

5. Turn: 

• Crankshaft 

(until TDC mark (3) is aligned with station 
ary pointer (4) 



6. Remove: 

• Tappet cover (intake) (1) 

• Tappet cover (exhaust) (2) 



ENGINE DISASSEMBLY 






11. Remove; 

• Cam sprocket (1) 

• Camshaft (2) 

NOTE: 



• Fasten a safety wire (3) to the timing chain to 
prevent if from falling into the crankcase. 

• Do not fall the stopper guide plate (4) into Ihe 
crankcase when removing the bolts (cam 
sprocket). 

12. Remove: 

• Chain guide (1) (exhaust) 




© 



s&w&ka 



*:■ N*/ 




7. Remove: 

• Cylinder head cover (1 

NOTE: 



Working in a crisscross pattern. loosen the bolts 
1/4 turn each. Remove them after all are loosened. 



8. Loosen: 

♦ Bolts (1) {cam sprocket) 





13. Remove: 
Pipe{i) 
O-Ring 

Bolts (2) 
Bolts (3) 
Bolts (4) 

NOTE: 

Working in a crisscross pattern, loosen the bolts 
1/4 turn each. Remove them after all are loosened. 



*S2^b 




9. Loosen: 

• Cap bolt (1) (chain tensioner 
10. Remove: 

• Chain tensioner (2) 




iSSSlSli 







14. Remove: 

• Cylinder head (1) 



4-9 



4-10 






ENGINE DISASSEMBLY 





15. Remove: 

• Gasket (1) (cylinder head) 

• Dowel pins (2) 



16. Remove: 
• Pipe(1) 



17. Remove: 

• Bolts (1) 

* Bolts (2) 

NOTE: 



Working in a crisscross pattern, loosen the bolts 
1/4 turn each. Remove them after all are loosened. 



ENGINE DISASSEMBLY 



ENG 


%m 




20. Remove: 

• Piston pincirclips (1) 

• Piston pin (2) 

• Piston (3} 

NOTE: 



Before removing the piston pin circlip, cover the 
crankcase with a clean rag to prevent the circlip 

from falling into the crankcase cavity. 
Before removing the piston pin, deburr the clip 
grooved and pin hole area. If the piston pin 
groove is deburred and piston pin is still difficult 
to remove, use the piston pin puifer. 



y* 



Piston pin pufler: 
P/N YU-01304, 90890-01304 



CAUTION; 



Do not use a hammer to drive the piston pi n out. 




18. Remove: 

• Cylinder {1) 



ROTOR AND STARTER DRIVERS 



NOTE: 



The AC magneto and starter drivers can be main- 
tained with the engine mounted. 




19. Remove: 

• Gasket (1) (cylinder 

• Dowel pins (2) 







1 . Remove: 
* Cover (1) 



4-11 



4-12 



ENGINE DISASSEMBLY 






3U«v.«.< 




- • (2) 01 





2. Remove: 

• Starter idle gear 1 (1 

• Needle bearing (2) 

• Shaft (3) 

• Gasket (4) 

• Dowel pin (5) 



3. Disconnect: 

• Neutral switch lead (1) 

4. Remove: 

• Crankcase cover (2) (left) 

NOTE: 



Working in a crisscross pattern, loosen the bolts 
1/4 turn each. Remove them after all are loosened. 



5. Remove: 

• Starter idle gear 2 (1 

• Needle bearing (2) 

• Shaft (3) 

• Gasket (4) (crankcase cover) 

• Dowel pins (5) 

• O-rings (6) 



6. Remove: 

• Nut{1) (rotor) 

NOTE: 



Loosen the nut (rotor) while holding the rotor with 
the rotor holder (2). 



f* 



Rotor holder: 
P/N YS-01880, 90890-01701 



CAUTION: 



Do not allow the rotor holder to touch the 
projection (3) on the rotor. 



ENGINE DISASSEMBLY 



ENG 


%m 








m 



'■^UiiiX&iM 1 ^ 





«t 





7. Remove: 

• Rotor (1) 

• Woodruff key (2) 

Use the rotor puller (3) and adapter (4) 




Rotor puller: 

PfN YU-33270, 90890-01362 
Adapter: 

P/N YM~04063~A> 90890-04063 



NOTE: „ 

Tighten the tool holding bolts, but make sure that 
the tool body is parallel with the rotor. If necessary, 
one screw may be backed out slightly to level tool 
body. 



8. Remove: 

• Wheel gear (i) 

• Needle bearing (2) 

• Washer (3) 



9- Remove: 

# Chain guide (1) 
t^a • Timing chain (2) 



OIL FILTER AND WATER PUMP 
NOTE: 



The water pump can be maintained with the engine 
mounted. 



1. Remove: 

♦ Oil fitter cover (1) 



4-13 



4-14 









ENGINE DISASSEMBLY 





2. Remove: 

• Oil filter (1) 

• O-rings (2) 



3. Remove: 

• Water pump cover (1) 



4. Remove: 
* O-ring (1 




ENGINE DISASSEMBLY 



ENG 






CLUTCH AND BALANCER GEAR 



NOTE: 



With the engine mounted, the clutch can be main< 
tained by removing the following parts: 

• Side pane! (R) 

• Clutch cable 

• Water pump housing 



1 . Remove: 

• Circlip (1) 

• Washer (2) 

• Pull lever (3) 

• Return spring (4) 

• Washer (5) 



2. Remove: 

• Crankcase cover (1 ) (right) 



NOTE; 

Working in a crisscross pattern, loosen the bolts 
1/4 turn each. Remove them after all are loosened. 



asflaffl^aw^^a 




5. Remove: 

* Water pump housing (1) 




3. Remove: 

• Gasket (1) (crankcase cover) 

• Dowel pins (2) 




m 



/ 



/ 







o /M 



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m 



V 



o 



/ 



6. Remove: 

Circlip (1 

Water pump gear (2) 
Pin (3) 
Circlip (4) 

Water pump housing (5) 
Impeller shaft (6) 




4. Remove: 

• Bolt(1) 

• Washer (2) 

• Pull lever axle (3) 
(from crankcase cover) 



4-15 



4-16 



©--Ob 




mt ®sar; 






^ 

v,'.. 










m 




^itF 



<^*~ 






ENGINE DISASSEMBLY 

5. Remove: 

Bolts ( 1 ) 

Clutch springs (2) 
Pressure plate (3) 
Washer (4) 
Bearing (5) 
Pull rod (6) 
Friction plate (7) 
Clutch plate (8) 
Cushion spring (9) 



NOTE: 

Working in a crisscross pattern, loosen the bolts 
1/4 turn each. Remove them after all are loosened. 




6. Straighten: 

• Lock washer tab 

7. Loosen: 

• Nut (1) (clutch boss) 



NOTE: — 

Loosen the nut (clutch boss) while holding the 

clutch boss with universal clutch holder (2). 



/- 



Universal clutch holder: 
P/N YM-91042, 90890-04086 



8. Remove: 

• Nut(1) (clutch boss) 

• Lock washer (2) 

• Clutch boss assembly (3) 

• Thrust plate (4) 

• Clutch housing (5) 



ENGINE DISASSEMBLY 



ENG 














9. Straighten: 

• Lock washer tabs (1) 
10. Loosen: 

• Nut (2) (crankshaft) 

• Nut (3) (balancer shaft) 



NOTE: 



Place a folded rag or aluminum plate between 
the teeth of the balancer drive gear and balancer 
gear- 
Take care not to damage the gear teeth. 



1 1 . Remove: 

Primary drive gear (1) 

Plate (2) 

Balancerdrivegear(3) 

Plate (4) 

Key (5) 

Plater washer (6) 

Plate (7) 

Balancer gear (8) 

Key (9) 



SHIFT LEVER AND OIL PUMP 

NOTE: — — 

• With the engine mounted, the oil pump can be 
maintained by removing the following parts: 

• Clutch cable 

• Water pump housing 



4-17 



4-18 








ENGINE DISASSEMBLY 



ENG 






Remove: 

• CircJip (1) 

• Shift lever (2) 

• Torsion spring (3) 

• Washer (4) 



Remove: 

• Stopper fever (1) 

• Cotlar (2) 

• Return spring (3) 



3. Remove: 

♦ Circlip (1 

• Oil pump gear (2) 



4. Remove: 

• Oil pump assembly (1 



5. Remove: 

• Gasket (1 

• O-ring (2) 



ENGINE DISASSEMBLY 



ENG 


%m 











6. Remove: 
« Circlip (1) 

• Collar (2) 

• Circlip (3) 



CRANKCASE (RIGHT) 

1. Remove: 

• Bolts (crankcase) 

El Crankcase (right) 
IB) Crankcase (left) 

NOTE: 



Loosen the bolts 1/4 turn each and remove them 
after all are loosened. 

Loosen the bolts starting with the highest 
numbered one. 

The embossed numbers in the crankcase desi- 
gnate the tightening sequence. 



NOTE: __ . 

Turn the shift cam to the position shown in the figure 
so that it does not contact the crankcase when 
separating the crankcase. 



2. Attach: 

• Crankcase separating tool (1) 



r> 



Crankcase separating tool: 
P/N YU-01135-A, 90890-01135 



3. Remove: 

• Crankcase (right) (2) 



4-19 



4-20 



ENGINE DISASSEMBLY 



ENG 


\m 




NOTE: 



Fully tighten the tool holding bolts, but make sure 

the tool body is parallel with the case. If necessary, 

one screw may be backed out slightly to level tool 

body. 

As pressure is applied, alternately tap on the 

front engine mounting boss, transmission shafts, 

and shift cam. 



ENGINE DISASSEMBLY 




ENG 


%m 



OIL STRAINER 

1. Remove: 

• Oil strainer (1) 

• Oil passage cover (2) 



CAUTION; 



Use soft hammer to tap on the case half. Tap 
only on reinforced portions of case. Do not tap 
on gasket mating surface. Work slowly and 
carefully. Make sure the case halves separate 
evenly. If one end "hans up" take pressure off 
the push screw, realign, and start over. If the 
cases do not separate, check for a remaining 
case screw or fitting. Do not force. 




2. Remove: 

• Gasket (1) (oil strainer) 




m 



oc^mti^^&#& 



A. Remove: 

• Dowel pins (1) 

• Dowel pin (2) 

• O-ring (3) 





Xf) 



**** 




BALANCER, TRANSMISSION AND SHIFTER 

1. Remove; 

• Shift shaft (1) 

• Shift shaft 2 (2) 



2. Remove: 

• Guide bar (1) (short) 

• Guide bar (2) (long) 

• Shift cam (3) 

• Shift fork 2 "C w (4) 

• Shift fork 3 "R" (5) 

• Shift fork 1 1" (6) 



3. Remove: 

• Main axle assembly (1) 



4-21 



4-22 



ENGINE DISASSEMBLY 





ENGINE DISASSEMBLY 



ENG 


%m 




,-*v. 



..— S& S*': 



(* 



1) 







4. Remove: 

♦ Drive axle assembly (1 

♦ Collar (2) 



5. Remove: 

• Balancer shaft (1 



6. Remove: 

• Neutral switch (1 







CRANKSHAFT 

1. Remove: 

• Crankshaft assembly (1) 

Use the crankcase separating tool (2) and 
adapter (3). 




Crankcase separating tool: 

P/N YU-01135-A, 90890-01135 
Adapter: 
P/N YM-04063-A, 90890-04063 




NOTE: , 

Tighten the tool holding bolts, but make sure that 
the tool body is vertical with the crankshaft. If 
necessary, one screw may be backed out slightly to 
level tool body. 



ROCKER ARM 



NOTE: 



With the engine mounted, the rocker arm can be 
maintained by removing the following parts: 

• Cowling 

• Seat 

• Fuel tank 

• Radiator 

• Exhaust pipes 

• Cylinder head cover 



1. Remove: 
• Plug{l) 



2. Remove: 

• Bolts (1) (rocker arm shaft) 






4-23 



4-24 




ENGINE DISASSEMBLY 

3. Remove: 

♦ Rocker arm shaft 

• Rocker arm 

NOTE: 



ENG 


%m 




Remove the rocker arm shaft by the slide hammer 
bolt (1) and weight (2). 




Slide hammer set: 
P/N YU-01083-A 

Slide hammer bolt; 

P/N 90890-01083 

Weight: 

P/N 90890-01084 



III 



ENGINE DISASSEMBLY 



ENG 


<*)JP 




2. Remove: 

• Valve cotters (1) 

NOTE: 



Remove the valve cotters while compressing the 
valve spring with the vaive spring compressor- 




Valve spring compressor: 
P/N YM-04019, 90890-04019 



VALVES 



NOTE: 



Before removing the internal parts (valve, valve 
spring, valve seat, etc.) of the cylinder head, the 
valve sealing should be checked. 



1. Check: 

• Valve sealing 

Leakage at valve seat -> Inspect the valve 
face, valve seat and valve seat width. 
Refer to the "INSPECTION ANO REPAIR 
-VALVE SEAT" section. 




"1 

j 
* 



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-<2) 



3. Remove: 

• Valve retainer (1) 

• Valve spring (2) 

• Valve (3) 

• Oil seal (4) 

• Spring seat (5) 

NOTE: „_ _ 

Identify each part position very carefully so that it 
can be reinstalled in its original place- 




Checking steps: 

• Pour a clean solvent (1) into the intake and 
exhaust ports. 

♦ Check the valve sealing. 

There should be no leakage at the valve seat (2). 



4-25 



4-26 



INSPECTION AND REPAIR 



ENG 



. 






V 






S 






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A 


^A 


K 




1 


1 




INSPECTION AND REPAIR 

CYLINDER HEAD 

1. Eliminate: 

• Carbon deposits 

(from combustion chamber) 
Use a rounded scraper. 

NOTE: 



Do not use a pointed tool to avoid damaging or 
scratching; 

♦ spark plug thread 

♦ valve seats 

♦ combustion chamber 

2. inspect: 

* Cylinder head 
Scratches/Damage -> Replace. 

♦ Water jacket 

Crust of minerals/Rust -* Eliminate. 

3. Measure: 

• Deformation 

Out of specification -» Rework the surface. 




5 



Cylinder head deformation: 
Less than 0.03 mm 



4. Surface: 

• Cylinder head 



Levelling: 

Level the cylinder head with wet 400 ~ 600 emery 
paper in a figure-8 direction. 

NOTE: 

To avoid removing too much material on one side 
only, turn the cylinder head a number of times. 






INSPECTION AND REPAIR 



ENG 


%m 



VALVES AND VALVE GUIDES 

1. Measure: 

• Clearance between stem and guide 




Internal diameter of valve guide (a) - 
Diameter of valve stem (b) 



Out of specification 
guide. 



Replace valve 



^ 


Clearance between stem and guide: 


Intake: 


0.010-0.037 
< Limit >: 0.08 mm 


Exhaust: 


0.025 ~ 0.052 
< Limit >: 0.10 mm 



(1) Bore gauge 

2. Replace: 

• Vatve guide 



Replacement: 



NOTE: 



Heat the cylinder head in an oven at 100"C to 
facilitate the removal and installation of the guides 
and to mainiain correct locking interference. 

• Remove the valve guide using the special punch 

• Install the new guide using the special installa- 
tion tool (2). 

• After installing the valve guide, bore with special 
tool (3) to obtain valve-guide free play. 




j^2J 6 mm guide valve puller: 


<Z | P/N YM-04064-A 


P/N 90890-04064 


6 mm valve guide installer: 


P/N YM-04065 


P/N 90890-04065 


6 mm valve guide borer: 


P/N YM-04066 


P/N 90890-04066 



4-27 



4-28 



INSPECTION AND REPAIR 



<§rt 



zrac 




x? 



45 1 




77T7 



77 




1 



777777777T? 



777777 




NOTE: ™ 

Reface the valve seat after replacing the valve 
guide. 

3. Clean the valve surfaces of the carbon depos- 
its. 

4. Inspect: 

* Valve seal surface 

Pitting/Wear -* Grind the valve seal 
surface, 

5. Measure: 

• Edge thickness (a) 

Out of specification -» Reface. 




^ 



Edge thickness limit: 
0,8 mm 



~] 



6. Check: 

• Valve stem tip 

Deformed, mushroom-shaped or with a 
higher diameter than the rest of the stem 
-> Replace valve. 

• Misalignment (valve stem) 

Out of specification -> Replace valve. 




s 



Stem offsettig limit: 
0.01 mm 



NOTE: 



Changing the valve, replace alsothevalveguide. 
Pulling the valve out, replace the oil seal. 



VALVE HOUSING 

1. Clean the valve surface and seat of carbon 
deposits. 

2. Inspect: 

• Valve seat 

Pitting/Wear -» Renew valve seat. 




INSPECTION AND REPAIR 



ENG 


\m 





3. Measure: 

• Valve seat width (a) 

Out of specification -> Renew valve seat. 




Valve seat width; 



Intake; 



0.9 -1.1 mm 



Exhaust: 



0,9 -1*1 mm 



Measurement stages: 

• Apply Prussian blue (Dykem) to the valve seat 

(1). 

• Install the valve in the cylinder head. 

• Press the valve onto the seat through the guide 
to leave a clear outline. 

• Measure the width of the valve seat. Where there 
is contatc between valve and seat the Prussian 
blue is wiped away. 

• If the valve seat is too narrow, wide or off-centre, 
the valve seat must be renewed. 



4. Renew: 

• Valve seat 

Use the special tool to renew the valve 
seat (1) with 30°, 45° and 60° mills. 



y- 



Valve seat milling unit; 
P/N. YM-91043 



CAUTION: ^____ 

Turning the milling tool, maintain uniform pres- 
sure (about 4-5 kg) to avoid leaving marks on 
the valve seat. 



4-29 



4-30 



INSPECTION AND REPAIR 




ENG 


%m 



Mill the valve seat as follows 


Section 


Mill 


A 


30° 


B 


45° 


C 


60° 



m 


c-;-: : :^ /^e 


1 J 


1 



Valve seat faults recorded by analysing the 
valve seal surface: 

[A] If the valve surface resembles that shown in 
the figure, this means that the valve seat is 
centred on the surface but is too wide. 



Intervention on the 

valve seat 


Desired effect 


Mill 
type: 


30° 


Reduce valve seat 
width to 1.0 mm 


60° 




[B] If the valve surface is like this, it means that the 
valve seat is centred on the valve surface but 

is too narrow. 



Intervention on the 
valve seat 


Desired effect 


Mill 
type: 


45° 


Increase valve seat 

width to 1.0 mm 





,.,,^x 


I ■ 





[C] If the vatve surface is like this, it means that the 
valve seat is too narrow and close to the edge 
of the valve. 



Intervention on the 

valve seat 


Desired effect 


Mill 
type: 


30° (before) 


Centring of seat 
and attainment of 1.0 
mm width 


45° 




[D] If the valve surface is like this, it means that the 
valve seat is too narrow and situated low down 
near the lower edge of the valve surface. 



Intervention on the 
valve seat 


Desired effect 


Mill 
type: 


60" (before) 


Centring of seat 
and attainment of 1 .0 
mm width 


45° 




INSPECTION AND REPAIR 



ENG 


%m 



5, Emery: 

• Principal valve surface 

• Valve seat 

NOTE: 



If the valve seat is renewed or the valve and guide 
replaced, the vatve seat and seal surface must be 

lapped. 




Lapping: 

• Apply rough-lapping compound to the valve seal 
surface. 



CAUTION: 



Make sure the lapping compound does n§t run 
into the space between the guide and valve 
stem. 




Apply oil to the molybdenum disulfide on the 

valve stem. 

Install the valve in the cylinder head. 



♦ Turn the valve until face and surface are not 
evenly polished. Then clean away all the lapping 
compound. 

NOTE: 

For best results, during lapping, repeatedly apply 
(light) pressure to the valve seat, turning the valve 
backwards and forwards by hand. 

♦ Apply a fine-lapping compound on the valve seal 
surface and repeat the procedures described 
above. 



NOTE: — 

Be sure to remove all the lapping compound from 
the valve surface after every lapping operation. 



4-31 



4-32 



INSPECTION AND REPAIR 




Apply Prussian blue (Dykem) to the valve sea! 
surface. 

Install the valve in the cylinder head- 
Press the valve onto the seat through the guide 
to leave a clear outline. 

Measure the valve seat width once more. If the 
width of the valve is out of specification alter and 
relap. 




VALVE SPRING 

1. Measure: 

♦ Free width of valve spring (a; 
Out of specification -» Replace. 



^/ ] Free width (a) of valve spring: 


Intake 


Exhaust 


32.63 mm 


36.4S mm 



t 


=< t 




r^u\ ■© 


/f>55 


— ±-\ 



2. Measure: 
• Spring load 

Out of specification -» Replace. 

(b) Length of loaded spring 



^ 


Valve spring load: 
Intake: 




(C)10.2~11.8kg 

(b) 27.50 mm 

Exhaust: 

(c) 12.3 -14.1 kg 

(b) 31 .00 mm 




3. Measure: 

• Inclination of spring (a; 

Out of specification -» Replace. 



£ 


Inclination of spring: 


Intake 


Exhaust 


Lower than 1.4 mm 


Lower than 1.6 mm 




INSPECTION AND REPAIR 



ENG 


%m 





® 




«T ■ — %Af™ \ 




z± <0 JlJL 


LJR. 





CAMSHAFT 

1. Inspect: 

• Cam eccentrics 

Pitting/Scratches/Blue colour 
camshaft. 



Replace 



2. Measure: 

♦ Cam eccentrics 

Out of specification -> Replace camshaft. 



« 




(a) 


(b) 


Intake: 


35.69-35.79 mm 


30.06-30.1 6 mm 


Exhaust: 


36.50-36.60 mm 


30.11-30.21 mm 



3. Measure: 

• Runout (camshaft) 

Out ot specification -» Replace. 




Runout (camshaft): 
Less than 0.03 mm 



4. Measure: 

• Camshaft-to-cap clearance 

Out of specification -» Measure bearing 
diameter (camshaft), 




^ 



CamshafMo-cap clearance: 
0.020-0.054 mm 



Measurement steps: 

• Install the camshaft onto the cylinder head. 

• Positione a strip of Plastigauge^ onto the 
camshaft. 

• Install the dowel pins and cylinder head cover. 




Bolt (cylinder head cover): 
10Nm(1.0kgm) 



4-33 



4-34 



INSPECTION AND REPAIR 








NOTE: 



Tighten the bolts (cylinder head cover) in a criss- 
cross pattern from innermost to outer. 
Do not turn the camshaft when measuring 
clearance with the Piastigauge' 1 *. 

Remove the cylinder head cover and measure 
width of the Plastigauge^. 




5. 



Measure: 

• Bearing diameter (a) (camshaft) 

Out of specification ** Replace camshaft 
Within specification -» Replace cylinder 
head. 




Bearing diameter (camshaft): 
22.967 -22.980 mm 




DECOMPRESSION 

1 . Inspect: 

• Spring (1) 
Damage -» Replace. 

• Decompression pin (2) 

• Decompression lever (3) 

• Decompression cams (4) 
Damage/Bends/Wear -» Replace. 

2. Check: 

• Decompression play 
Play exists -4 Replace. 




INSPECTION AND REPAIR 





ROCKER ARM AND ROCKER ARM SHAFT 

1. Inspect: 

• Rocker arm shaft 

Blue colour/Grooves -» Replace shaft and 
check lubrication system. 



2. inspect: 

• Rocker arm shaft slot (1 ) 

• Surface in contact with cam eccentric (2) 

• Adjuster surface (3) 
Pitting/Wear/Scratches/BJue colour-* Re- 
place and check lubrication system. 



3. Measure: 

• Rocker arm-shaft clearance 



Rocker arm-shaft clearance = 



Internal diameter (a) of rocker arm 
External diameter (b) of shaft 



Out of specification -♦ Replace assembly. 



® 






=Sp ~^ 


y 




s 



Rocker arm shaft clearance: 
0.009 ~ 0.042 mm 




CAMSHAFT CHAIN, SPROCKET AND CHAIN 
GUIDE 

1 . Inspect: 
• Chain 

Stiffness/Cracks -> Replace timing chain 

and sprocket. 



4-35 



4-36 



INSPECTION AND REPAIR 




ENG 


\m 




2. 


Inspect: 




• Sprocket 




Wear/Damage -4 Rei 




and sprocket. 


(1) 


1/4 tooth (maximum) 


(2) 


New sprocket tooth profile 


(3) 


Roller 


(4) 


Sprocket 



Replace timing chain 




CAMSHAFT CHAIN GUIDE 

1 , Inspect: 

♦ Lateral chain guide (exhaust) (1) 

• Lateral chain guide (intake) (2) 
Wear/Damage -» Replace. 





CYLINDER AND PISTON 

1. Eliminate: 

• Carbon deposits 

(from the piston crow and ring grooves) 

2. Inspect: 

• Piston wall 
Wear/Scratches/Damage -» Replace. 

3. Eliminate: 

• Score marks and Jacquer deposits 
(from the side of the piston) 

Use a 600 - 800 grit wet sandpaper. 

NOTE: -- 

Sand in a crisscross pattern. Do not sand exces- 
sively. 

4. Inspect: 

• Cylinder water jacket 

Crust of minerals/Rust -» Remove. 

• Cylinder wall 

Wear/Scratches ~> Rebore or replace. 

5. Measure: 

• Piston-to-cyiinder clearance 



INSPECTION AND REPAIR 



ENG 


%m 




Measurement stages: 

First stage""] 



• Measure cylinder bore "C" with a cylindergauge. 
(1) 50 mm from top of cylinder 

NOTE: 

Measure bore parallel and at right angles to the 
driving shaft. Then calculate average measure- 
ment 



m 




Standard 


Wear 
limit 


Cylinder 
bore H C" 


100.005 -100.045 mm 


100.1 mm 


r X + Y 



If the measurements are out of tolerance, re- 
place the cylinder liner, piston and circlips all 

together. 




Second stage [ 



• Measure diameter "P* of the piston skirt with a 

micrometer. 
(1 ) 2.5 mm from the lower edge of the piston 




Piston skirt M P" size: 



Standard 



99.945 - 99.985 mm 



If the measurements are out of tolerance, re- 
place the piston and circlips all together. 



4-37 



4-38 



INSPECTION AND REPAIR 





Third stage 



Calculate the ptston-cyitnderclearance according 
to the following formula. 



Piston-cylinder clearance = 



Cylinder boring "C"- 
Piston skirt diameter "P" 




Piston-cylinder clearance: 
0.050-0.070 mm 

Maximum limit: 
0.15 mm 




' vi^V)J\V^ > J ^V* +&+< 



♦ if the measurements are out of tolerance, rebore 
or replace the cylinder, and replace the piston 
and piston ring as a set. 



r * 



* * * w * * * 



INSPECTION AND REPAIR 



ENG 


%• 



PISTON RINGS 

1. Measure: 

• Lateral clearance of rings 

Use a thickness gauge. 

Out of specification -* Replace piston and 

piston ring as a set. 

NOTE: _^^__ 

Before measuring lateral clearance, remove car- 
bon deposits from the piston ring seats and from the 
rings themselves. 



s 


Piston ring lateral clearance: 


Upper ring 


0.04 ~ 0.08 mm 


Lower ring 


0.03 - 0.07 mm 

i 



_ * — fc - *^ I 




j® 


■ ^^-^'i 


rf'^^^^^i*^ 




V 


/ 

*• 





2. Position: 
• Ring 

(into cylinder) 

NOTE: 



Fit each ring into the cylindsrand push it to about20 
mm from the top edge of the cylinder. Push the ring 
into the cylinder with the piston so that it is perfectly 
perpendicular to the cylinder axis. 

(a) 20 mm 

3. Measure: 

• Ring tip port 

Out of specification -> Replace. 

NOTE: . . . . 

It is impossible to measure the oil scraper tip port. 
I! the oil scraper port appears too large, replace alt 
three rings as a set. 



<% 


Piston ring tip port 
(fitted into cylinder) 


Upper ring 


0.30 ~ 0.45 mm 


Lower ring 


0.30-0.45 mm 


Oil scraper (tracks) 


0.20 ~ 0.70 mm 



4-39 



4-40 



INSPECTION AND REPAIR 





® 
























PISTON PIN 

1. Check: 

♦ Piston pin 

Bluecolour/Grooves -> Replace and check 
lubrication system. 



2. Measure: 

• External diameter (a) of pin 
Out of specification -> Replace 




^ 



External diameter (pin): 
21.991 -22.000 mm 



3. Measure: 

• Clearance between piston pin and piston 
pin seat 

Out of specification -» Replace. 

• Calculate the piston pin-piston clearance 
according to the following formula: 



Clearance between piston pin and 
piston = 

Diameter on piston (b) - 

Diameter of pin (a) 




Clearance between piston pin and 
piston: 
0.004 -0.024 mm 

Maximum clearance: 
0.07 mm 



INSPECTION AND REPAIR 



ENG 


%m 



F 


* 


Tiff 


c^ 5 


E-- 


■ 


It 




J L 






A 







CRANKSHAFT 

1. Measure: 

• Crank width (A) 

Out of specification -» Replace crankshaft- 




5 



Crank width: 
74.95 - 75.00 mm 



Runout (C) 

Out of specification -» Replace crankshaft 

and/or width bearing. 




s 



Runout limit: 
0.03 mm 



Small end free play (D) 

Out of specification *» Replace big end 

bearing, crank pin and/or connecting rod. 




Small end free play: 
0.8 mm 



Big end radial clearance (E) 

Out of specification -» Replace connecting 

rod, big end bearing and/or crank pin. 




^ 



Big end radial clearance: 
0.01 - 0.025 mm 



Side clearance (F) 

Out of specification -* Replace connecting 

rod. 




Big end side clearance: 
0.35 - 0.65 mm 




Crankshaft reassembling point: 

The crankshaft (1) and the crank pin (2) oil 
passages must be properly interconnected with 

a tolerance of less than 1 .0 mm. 



4-41 



4-42 




INSPECTION AND REPAIR 






BALANCER DRIVE GEAR AND BALANCER 
GEAR 

1 . Inspect: 

♦ Balancer drive gear teeth (1) 

• Balancer gear teeth (2) 
Wear/Damage -> Replace both gears. 



INSPECTION AND REPAIR 



ENG 


\m 



When turning the starter wheel gear clockwise 
El, the starter clutch and the wheel gear should 
be engaged. 

If not, the starter clutch is faulty. Replace it. 
When turning the starter wheel gear counter- 
clockwise ELthestarterclutchgearshoutdturn 
freely. 
If not, the starter clutch is faulty. Replace it. 




Check: 

• Match marks (1) 

If they are not aligned -» Align match marks 

as shown. 




CD 



© 



ELECTRtC STARTER DRIVE 

1. Inspect: 

• Starter idle gear 1 teeth (1 

• Starter idle gear 2 teeth (2) 

• Starter wheel gear teeth (3) 
Burrs/Chips/Roughness/Wear -> Replace. 





PRIMARY DRIVE 

1. Inspect: 

• Primary drive gear teeth (1) 

• Primary driven gear teeth (2) 
Wear/Damage -> Replace both gears. 
Excessive noises during operation -* Replace 
both gears. 





2. Inspect: 

• Starter wheel gear 
(contacting surfaces) 
Pitttng/Wear/Damage 



Replace. 



3. Check: 

• Starter clutch operation 




Checking steps; 

• Install the starter wheel gear to the starter 
clutch, and hold the starter clutch. 



CLUTCH 

1. Inspect: 

• Friction plates 

Damage -* Replace friction plate as a set. 

2. Measure: 

• Friction plate thickness 

Out of specification -» Replace friction plate 

as a set. 

Measure at all four points. 



^ 




Thickness 


I Wear 
limit 


Type "A" 

(2 pes.) 


2.94 ~ 3.06 mm 


2.8 mm 


Type "B" 
(6 pes.) 


2.74 ~ 2,86 mm 


2.6 mm 



4-43 



4-44 



INSPECTION AND REPAIR 




ENG 


\m 



3. 



Inspect: 

• Clutch plates 

Damage -» Replace clutch plates as a set. 



Measure: 

• Clutch plate warpage 

Out of specification -* Replace clutch plate 

as a set. 

Use a surface plate and feeler gauge. 




Clutch plate warp limit: 
Less than 0,2 mm 



5. Inspect: 

• Clutch springs 

Damage -» Replace springs as a set. 




INSPECTION AND REPAIR 



ENG 






■■^'««"W:#^iiU!j™* 



VI* 





:.:..V,lll'.- ::..>;, ;■:.. ■ 

wmr 




8. Inspect: 

• Clutch boss splines 

Scoring: 

Moderate -» Deburr. 

Accentuated -» Replace clutch boss. 

NOTE: „ ■ 

Scoring on the clutch boss splines will cause erratic 
operation. 



9. Check: 

• Circumferential play 

Free play exists -> Replace. 



10. Inspect: 

♦ Gear teeth {1 ) (pull (ever axle) 

• Gear teeth (2) (pull rod) 

Wear/Damage ** Replace as a set. 







> c 


i 






..... 


tH 






v-| 


111-!: 


' ; ■ i i 


' ' I ' ! .- 




, _ _ . _ J V — * — ■*—— 


*f '' ! * 1 

i/ 
J® 


' 1 * . ~? 

f/^ 1 




1 

i 


T\(\\f\f\i 

*■ — -» 




6. Measure: 

• Clutch spring free length (a) 

Out of specification -> Replace springs as 
a set. 




Free length (clutch spring): 
42.8 mm 

< Limit: 40.8 mm > 



7. Inspect: 

• Dogs on the clutch housing 

Scoring/Wear/Damage (on edges): 

Moderate -> Deburr. 

Accentuated -» Replace clutch housing. 

NOTE: m 

Scoring on the clutch housing dogs will cause 
erratic operation. 




11. Inspect: 

♦ Bearing (1) (pull rod) 
Wear/Damage -» Replace. 



4-45 



4-46 





SiiiiP 




jst"s:"> >' 













liBff:'..,: 5 * V: ■ !::■;. 

v.«aP Si " : 





ENG 


%m 



INSPECTION AND REPAIR 



TRANSMISSION AND GEARBOX 

1. Inspect: 

• Gear fork cam pin (1) 

• Gear fork pawl (2) 
Lines/Creases/Wear-» Replace. 




INSPECTION AND REPAIR 



ENG 


%m 



2. 



3. 



4. 




Inspect: 

• Drum groove 

• Gear cam pins 
Wear/Damage -» Replace. 



Check: 

• Gear fork movement 

Rough functioning •* Replace gear forks 

and/or guide bars. 



Inspect: 

• Guide bar 

Turn on a flat surface 
Curvature -» Replace. 



A WARNING 



Do not attempt to straighten a deformed guide 
bar. 





'm 



6. Inspect: 

• Gear teeth 

Brown colouring/Pitting/Wear -» Replace. 

• Mating clutches 

Rounded edges/Cracks/Missing frag- 
ments -> Replace. 



7. Check: 

• Proper mating of each gear (with corre- 
sponding part} 

• Gear movemenl 
Roughness -» Replace. 



Transmission gear assembly stages: 

• Ft( the 2nd pinion gear (1) to the propeller shaft 
(2) as shown in the figure. 



8. Inspect: 

• Spring {1} 

Damage ■* Replace. 

• Shift lever (2) 

Damage/Bends/Wear 



Replace. 



9. inspect 

• Shift shaft: 

Benl/Wear/Damage -» Replace. 



F J 




5. Measure: 

• Transmission shaft eccentricity. 
Use the centring tool and micrometer 
Out of specification -» Replace shaft. 




Eccentricity limit: 

0.08 mm 



A WARNING 



\ 



Do not attempt to straighten a deformed shaft. 




10. Inspect: 

• Stop lever (1) 

The roller rotates jerkily -* Replace. 
Bent/Damage ~» Replace. 

• Return spring {2) 
Damage/Cracks -» Replace. 



4-47 



4-48 




m 



y 



o 



INSPECTION AND REPAIR 




•-W7 


S) 


i' 

Y// a 


3 '^//yyjy* 


\^y//.\ 




OIL PUMP, WATER PUMP AND STRAINER 

1. Measure: 

• Clearance between rotors (a) 
Between (he internal rotor (1) and (he 
external rotor (2) 

• Lateral clearance (b) 

Between (he external rotor (2) and the 

pump stator (3) 

Out of specification -> Replace oil pump. 



5 


Oil pump clearances: 


Clearance between rotors (a) 


0.12 mm 


Lateral clearance (b) 


0.03 -0.08 mm 



2. Inspect: 

• Oil pump drive gear (1) 

• Oil pump driven gear (2) 
Wear/Cracks/Damage -» Replace. 

3. Inspect: 

• 0-ring(1) 

• Water pump housing (2) 

• Water pump gear (3) 
Cracks/Wear/Damage -* Replace. 




INSPECTION AND REPAIR 



ENG 


%m 




OIL DELIVERY PIPES 

1. Inspect: 

• Oil delivery pipes 

Cracks/Damages -> Replace. 

Clog -* Blow out with compressed air. 



CRANKCASE 

t. Thoroughly wash the case halves in mild 
solvent. 

2. Clean all the gasket mating surface and crank- 
case mating surface thoroughly. 

3. Inspect: 

• Crankcase 
Cracks/Damage -* Replace. 

• Oil delivery passages 

Clog -» Blow out whit compressed air. 



BEARING AND OIL SEAL 

1. Inspect: 

• Bearing 

Clean and lubricate, then rotate inner race 
with finger. 
Roughness -* Replace. 

2. Inspect: 

• Oil seal 
Damage/Wear-* Replace. 




4. Inspect: 

• Oil strainer (1 

Damage -» Replace. 



CIRCLIP AND WASHER 

1. Inspect: 

• Circlip 

• Washer 
Damage/Free play/Warp 



Replace. 



4-49 



4-50 



ENGINE ASSEMBLY AND SETTING 




ENGINE ASSEMBLY AND SETTING 



VALVES AND ROCKER ARMS 



(1) 


Rocker arm n. 2 


(6) Upper valve spring retainer 


(2) 


Wave washer 


(7) Oil seal 


(3) 


Rocker shaft (intake) 


(8) Valve spring 


(4) 


Rocker arm n. 1 


(9) Valve (intake) 


(5) 


Valve cotters 


(10) Lower valve spring retainer 



(11) Rocker shaft (exhaust) 

(12) Rocker arm n. 4 

(13) Rocker arm n. 3 

(14) Rocker shaft (exhaust) 

(15) Valve (exhaust) 



B 



VALVE SPRING TILT LtMIT: 
Inner spring: 
2.5° or 1.4 mm (0.055 in) 
Outer spring: 
2.5° or 1.6 mm (0.063 in) 



VALVE CLEARANCE (COLD): 
Intake: 0.10-0.15 mm (0.004-0.006 in) 
Exhaust: 0.15-0.20 mm (0.006-0.008 in) 



14 Nm (1.4m«kg f 1 ft-lb) 



14 Nm (1.4nrkg, 10fWb) 



E 




1 



D 




STEM RUNOOT LIMIT 
0.01 mm (0.0004 in) 



VALVE SEAT WIDTH: 
0.9 -1.1mm (0.035-0.043 in) 




ENGINE ASSEMBLY AND SETTING 



ENG 


%m 




WARNING 




For engine reassembly, replace the following 
parts whit new one. 

• O-ring 

• Gasket 

• Oil sea! 

• Key 

• Lock washer 

• Circlip 

VALVES 

1. Burrs: 

• Valve stem head 

Polish the valve stem head with an oil 
stone. 



2. Apply; 

• Molybdenum disulfide grease (to the vafve 
stem and oil seal) 




3. Install: 

• Lower valve cap (1) 

• Oil seal (2) 

• Valve (3) 

• Valve spring (4) 

• Upper valve cap (5) (into cylinder head) 



4-51 



4-52 




ilit 



ENGINE ASSEMBLY AND SETTING 



NOTE: 







Make sure that the each valve is installed in its 

original place by reference to it embossed 

identification mark, as follows: 

Intake: 3YF • 

Exhaust: 3YF 

Install the valve spring with larger pitch (6) facing 

upward. 

(7) Smaller pitch. 



4. Install: 

♦ Valve cotters (1) 

NOTE: 



Install the valve cotters while compressing the 
valve spring with the valve spring compressor. 




Valve spring compressor: 
P/N YM-04019, 90890-04019 



5. Secure the valve cotters on to the valve stem 
by tapping it lightly with a piece of wood. 

CAUTION: 
Do not hit so much as to damage the valve. 



ENGINE ASSEMBLY AND SETTING 



ENG 


%m 






ROCKER ARMS 

1. Lubricate: 

• Rocker shaft 
(with engine oil) 

2. Install: 

• Rocker arm 

• Rocker shaft 




Screws (1) (rocker shaft): 
tONm(I.Omkg) 



NOTE: 



Each rocker arm is numbered. 



(1) 
(2) 

(3) 
(4) 



#1 
#2 
#3 

#4 



3. Install: 
• Cap(1) 



4-53 



4-54 



ENGINE ASSEMBLY AND SETTING 



CRANKSHAFT 




(1) 


Connecting 


rod pin 


(2) 


Crank (left) 




(3) 


Connecting 


rod 


(4) 


Bearing 




(5) 


Bearing 







ENGINE ASSEMBLY AND SETTING 



ENG 


\m 



A 


CRANK WIDTH: 
74.95-75.00 mm (2.950-2.953 in) 


B 


RUNOUT LIMIT: 
0.03 mm (0.001 2 in) 


C 


SMALL END FREE PLAY: 
0.8 mm (0.031 in) 


D 


BIG END RADIAL CLEARANCE: 
0.01-0.025 mm (0.0004-0.0010 in) 


E 


BIG END SIDE CLEARANCE: 
0.35-0.65 mm (0.013-0.026 in) 




m 



B6307SH2-C4 



N37-45-22 




B6307SH2-C4 



150 Nm (15.0 rmkg, 110 fMb) 







1. Attach: 

• Crankshaft installing tool 





Crankshaft installer set: 
P/N. YU-90050 

Crank pot spacer (1): 
P/N. YM-91044 
P/N. 90890-04081 

Adapter #10 (2): 
P/N. YM-90069 
P/N. 90890-04059 

Crankshaft installer pot (3): 
P/N. 90890-01274 

Crankshaft installer bolt (4): 
P/N. 90890-01275 

Spacer (5): 
P/N. 90890-01288 



NOTE: __™_______ 

Hold the connecting rod at top dead center with one 
hand while turning the nut of the installing tool with 
the other. Operate the installing tool until half of the 
crankshaft bearing (6) is inserted into the crankcase 
as shown. Then, add the spacer (5) as shown and 
operate the installing tool unti! the crankshaft 
bottoms against the bearing. 



CAUTION: 



To protect the crankshaft against scratches or 
to facilitate the operation of the installation 
apply the grease to the oil seal lips, and apply 
the engine oil to each bearing. 



4-55 



4-56 



ENGINE ASSEMBLY AND SETTING 



BALANCER SHAFT AND TRANSMISSION 



ENG 






ENGINE ASSEMBLY AND SETTING 



SHIFTER 



ENG 


\m 



(1) Sprocket 

(2) Oil seal 

(3) Bearing 

(4) Second wheel gear 

(5) Secondary shaft 

(6) Fifth wheel gear 

(7) Third wheel gear 



(8) Fourth wheel gear 

(9) First wheel gear 
{10} Bearing 

{11} Bearing 

(12) Second sprocket gear 

(13) Fifth sprocket gear 
{14) Third sprocket gear 



(15) Fourth sprocket 
gear 

(16) Main shaft 

(17) Bearing 

(18) Bearing 

(19) Bearing 
{20) Bearing 



(1) 


Guide bar (long) 


(7) 


Gear shalt #2 


(2) 


Selector fork #3 "R" 


(8) 


Gear shaft #1 


(3) 


Selector fork #1 1' 


(9) 


Oil seal 


(4) 


Gear cam 






(5) 


Guide bar (short) 






(6) 


Selector fork #2 "C" 







B6305 



10Nm(1.0m«kg,7.2ft«lb) 



B6004 



B6305NRX1C3 



B 




C USE NEW ONE 



.0 m«kg, 80 1Mb) 



DRIVE AXLE RUNOUT LIMIT: 
0.08 mm (0.003 in) 



MAIN AXLE RUNOUT LIMIT: 
0.08 mm {0.003 in) 



B6004 



B6305SH2| 



12Nm(1.2m»kg,8.7fWb) 




3 * 



10Nm{1.0nvkg,7.2fflb) 



4-57 



4-58 



ENGINE ASSEMBLY AND SETTING 



ENG 


\m 





^.rffr^m Vfe 







BALANCER, TRANSMISSION AND SHIFTER 

1. Install: 

• Neutral switch (1) 



2. Install: 

• Balancer shaft (1} 



.*** 



■■ y m ■£&,$& 



ENGINE ASSEMBLY AND SETTING 



ENG 


%» 




6. Install: 

• Shift fork #1 T"(1) 

• Shift fork #3 "R" (2) 

• Shift fork #2 "C" (3) 

• Gear cam (4) 

• Guide bar (long) (5) 

• Guide bar (short) (6) 

NOTE: 

Install the shift forks with the embossed mark on 
each shift fork facing right side of the engine. 




M 



***£■; 




3. Install: 

♦ Cottar (1) 

• Drive axle a$sembly (2) 



4. Install: 

• Main axle assembly (1) 





7. Install: 

• Shift shaft #2(1) 

• Shift shaft #1 (2) 



8. Check: 

• Transmission operation 

Unsmooth operation -> Repair. 



5. Apply: 

♦ Engine oil 
(onto guide bars) 



4-59 



4-60 



OIL STRAINER 

(1) Oil strainer 

(2) Oil duct oil 

(3) Gasket 



ENGINE ASSEMBLY AND SETTING 



ENG 


%m 




ENGINE ASSEMBLY AND SETTING 



CRANKCASE 




(1) 


Bearing cover 


■ piate 


(2) 


Lock plate 




(3) 


Crankcase ventilation hose 


(4) 


Clamp 




(5) 


Crankcase 




(6) 


Collar 





(7) Dowel pin 

(8) Dowel pin 

(9) O-ring 



ENG 


%m 




A TIGHTENING SEQUENCE: 





7 Nm (0.7 rmkg, 5.1 ft-lb) 



10Nm(1.0m-kg,7.2fflb) 



B 




SEALANT (QUICK GASKET)*: 
YAMAHA BOND NO. 121 5 e 



4-61 



4-62 



ENGINE ASSEMBLY AND SETTING 





SHIFT LEVER AND OIL PUMP 



(1) 


Stopper lever 


(6) Torsion spring 


(2) 


Collar 


(7) Gasket 


(3) 


Torsion spring 


(8) O-ring 


(4) 


Collar 


(9) Oil pump 


(5) 


Shift lever 


(10) Oil pump gear 



10 Nm(1.0 imkg, 7.2 1Mb) 




10 Nm (1.0 m-kg, 7.2 fftb) 



ENGINE ASSEMBLY AND SETTING 



ENG 


%m 








ENGINE OIL PUMP SUCTION 

1. install: 

• Gasket (1) 

• Oil pump suction (2) 

• Oil passage cover (3) 




Screw (pump suction): 
7 Nm (0J mkg) 

Screw (oil passage cover): 
7 Nm (0.7 mkg) 



CRANKCASE 

1. Apply: 



Bonding agent 

(on the semicrank mating surfaces) 




Bonding agent (Quick Gasket) ®: 
PfU. ACC-11001-01 

Yamaha bond N°1215®: 
P/N. 90890-85505 



NOTE: „ 

Do not allow any sealant to come in contact whit the 
oil gallery. 

2. Install: 

• O-ring (1) 

• Dowel pin (2) 

• Dowel pins (3) 

3. Assemble the left semicrank to the right 
semicrank- Beat gently with a soft hammer. 

NOTE: . 

Turn the gear cam as shown in the figure so that it 
does not interfere with the crankcase during 
assembly. 

CAUTION: _ _^_ 

Before installing and tightening the fastening 
screws, be sure that the transmission is work- 
ing properly by hand, turning the gear cam in 
both directions. 



4-63 



4-64 



ENGINE ASSEMBLY AND SETTING 










4. Tighten; 

• Screws (crankcase) (1 



14} 



NOTE: 



Tighten the screws beginning with the one with 

the lowest number. 

Install the cable clamp on the bolt No. 4 




Screw (crankcase) (4): 
10 Nm{1.0 mkg) 



5. Apply: 

♦ 4-stroke engine oil 

(to the connecting rod pin, the bearing and 

the oil passage) 

6. Check: 

* Gearbox and transmission functioning 
Jerky functioning -» Repair. 



SHIP LEVER AND OIL PUMP 

1. Install: 

• Circlip (1} (to drive axle) 

• Collar (2) 

• Circlip (3) 



Apply 

• 4-stroke engine oil 

(to the oil pipes in crankcase) 



CAUTION: 



To avoid damage to the engine, lubricate the oil 
pump pipes in the crankcase liberally with 4- 
stroke engine oil. 



3. Apply: 

• 4-stroke engine oil 
(to the oil pump pipes) 



ENGINE ASSEMBLY AND SETTING 



ENG 


%m 




m 



/ 



®pp 




/ 






4. 



Install: 

♦ Gasket (1) 



O-rings (2} 

Oil pump (3) 

Oil pump gear (4) 

Circlip (5) 




Screw (oil pump): 
10 Nm(1.0 mkg) 



5. Install: 

♦ Spring (1) 
« Collar (2) 

• Stop lever (3) 




Stop lever screw (4): 
10Nm(1.0mkg) 



NOTE: ___ 

PSace the stop lever and the spring in the correct 
position. 



6- Install: 

• Flat washer (1) 

♦ Spring (2) 

♦ Shift lever (3) 

• Circlip (4) 



NOTE: 

When installing the shift lever, align the mark on the 
lever with that on the shitf shaft. 



4-65 



4-66 



ENGINE ASSEMBLY AND SETTING 



ENG 


\» 




BALANCER SHAFT GEAR 

(1) Key 

(2) Balancer shaft gear 

(3) Plate 

(4) Lock washer 

(5) Nut 

(6) Washer 

(7) Key 



(8) Plate 

(9) Balancer shaft transmission gear 

(10) Plate 

(11) Primary transmission gear 

(12) Lock washer 

(13) Nut 



ENGINE ASSEMBLY AND SETTING 



ENG 


\m 



CLUTCH 




(1) Spring 


(9) Friction piate (type B) 


(2) Pressure plate 


(10) Clutch boss 


(3) Push rod 


(11) Thrust plate 


(4) Push lever 


(12) Gear assy 


(5) Push lever axle 


(13) Primary transmission gear 


(6) Friction plate (type A) 




(7) Clutch boss spring 




(8) Clutch plate 





USE NEW ONE 



60 Nm(6.0 m*kg T 43fflb) 



USE NEW ONE 





120 Nm (12.0 m*kg, 85 fWb) 



A FRICTION PLATE: 


Type 


Thickness 


Wear Limit 


A 
2 pes. 


2.94-3.06 mm 
(0.116-0.120 in) 


2.8 (0.110 In) 


B 

6 pes. 


2.74-2.86 mm 
(0.108-0.113 in) 


2.6 mm (0.102 in) 
2.6 



B 



CLUTCH SPRING MINIMUM 
FREE LENGTH: 
40.8 mm (1.606 in) 



CLUTCH PLATE 
WARPAGE LIMIT: 
0.2 mm (0.008 in) 



8Nm(0.8m*kg,5.8fflb) 



6.5 Nm (0.65 m*kg, 4.7 fMb) 



120Nm(12.0m«kg,85fWb) 



D USE NEW ONE 




A USE NEW ONE 



90Nm(9.0rmkg,65fHb) 



4-67 



4-68 



ENGINE ASSEMBLY AND SETTING 





ENGINE ASSEMBLY AND SETTING 






*i. 




CLUTCH AND BALANCER GEAR 

1. Install: 

• Key(1) 

• Balancer gear (2) 

• Plate (3) 

• Lock washer (4) 

• Nut (5) (balancer gear) 

• Plate washer (6) 

• Key/7) 

• Piatt {8} 

• Balancer drive gear (9) 

• Plate (10) 

• Primary drive gear (1 1 ) 

• Lock washer (12) 

• Nut (13) (primary drive gear) 




Nut (balancer gear): 

60Nm(6.0mkg) 
Nut (primary drive gear): 

120 Nm (12.0 mkg) 



NOTE: 



When installing the drive gear, align the punched 
mark (14) on the drive gear with the punched 
mark (15) on the balancer gear- 
Place a folded rag or aluminum plate between 
the teeth of the balancer drive gear and balancer 
gear. 
Take care not to damage the gear teeth. 



2. Bend the lock washer tab along the nut fiat 
(16). 



ENG 


\» 






3. Apply; 

• Engine oil 

(onto bearing and gear teeth) 

4. Install: 

• Clutch housing (1) 

• Thrust plate (2) 

• Clutch boss assembly (3) 

• Lock washer (4) 

• Nut (5) (dutch boss) 

NOTE: 

Fit the tabs of the lock washer to the groove of the 
clutch boss. 



5. Tighten: 

♦ Nut(l) {clutch boss) 

NOTE; „ -.. .. 



Tighten the nut (clutch boss) while holding the 

clutch boss with the universal clutch holder (2). 




Universal clutch holder: 
P/N YM-91042, 90890-04086 




Nut (clutch boss): 
90 Nm (9,0 mkg) 



6. Bend: 

• Lock washer tab 
(along nut flat) 

7. Apply: 

• Molybdenum disulfide grease 
(onto gear teeth of pull rod) 

• Engine oil 

(onto bearing pull rod) 



4-69 



4-70 




ENGINE ASSEMBLY AND SETTING 



8. install: 

Friction plates (1) 
Clutch plates (2) 
Cushion spring (3) 
Pull rod (4) 
Bearing (5) {pull rod) 
Washer (6) 
Pressure plate (7) 
Clutch springs (8) 
Bolts (9) 






NOTE: „_ 

Install the clutch plates and friction plates alternately 
on the clutch boss, starting with a friction plate and 
ending with a friction plate. 

CAUTION: _^ 

• Thefriction plates (type A)(10)withthe larger 
of the inside diameter must be installed in the 
second and last places. 

• The cushion spring (11) must be placed on 
the inside of the second friction plate. 



« 




Friction plate 


Type "A" 


Type "B" 


Quantity 


2 pes 


6 pes 


Inside 
diameter "D" 


116 mm 


113 mm 

— - 




ENGINE ASSEMBLY AND SETTING 



ENG 


%m 





— s&%« 






NOTE: 

Align the punched mark (1 2) on the clutch boss with 
the arrow mark on the clutch pressure plate (13). 



\ 



Screw (pressure plate): 
8 Nm (0.8 mkg) 



9. Apply: 

♦ Lithium soap base grease 

(onto seal lips in crankcase cover) 

• Engine oil 

(onto bearings in crankcase cover) 



10. Install: 

• Pull lever axle (1) 

♦ Washer (2) 

t Bolt (3) 




\ 



Bolt (pull lever axle): 
6.5 Nm (0.65 mkg) 



11. Install: 

• Gasket (1) (crankcase cover) 

• Dowel pins (2) 



12. Install: 

• Crankcase cover (1) (right) 




Bolt (crankcase cover): 
10 Nm (1.0 mkg) 



NOTE: _™___ 

Tighten the bolts {crankcase cover) in a crisscross 
pattern. 



4-71 



4-72 




ENGINE ASSEMBLY AND SETTING 



13. Install: 

• Washer (1) 

• Return spring (2) 

• Pull lever (3) 

• Washer (4) 

• Circlip (5) 



ENG 




© 





ENGINE ASSEMBLY AND SETTING 




ENG 


%m 



3. Install: 

• O-rtng (1) 




NOTE; 




(5) 





Make sure thai the mark (6) on the pull lever is 

aligned whit the embossed mark (7) on the 

crankcase while pushing the pull lever. If not, 

change the pull lever position. 

Install the pull lever whit the "UP" mark (8) facing 

upward. 




OIL FILTER AND WATER PUMP 

1. Install: 

Impeller shaft (1) 

Water pump housing (2) 

Circlip (3) 

Pin (4) 

Water pump gear (5) 

Circlip (6) 



NOTE: 

install the water pump with embossed side (7) 
facing to inside. 









8 INSIDE 



2. Apply: 

♦ Molybdenum disulfide grease 
(onto impeller shaft end) 




Install: 

• Water pump housing {1 ) 

• Water pump cover (2) 




A 



Bolt (water pump); 
10Nm(1.0mkg} 



5. Install: 

• Oil fitter (1) 

♦ O-rings (2) 



CAUTION: 



Install the oil filter as shown. 



[Bj INSIDE 

6. Install: 

♦ Oil filter cover (t) 




Bolt (oil filter cover): 
1QNm(1.0mkg) 



4-73 



4-74 



ENGINE ASSEMBLY AND SETTING 



ENG 


%m 




STARTER GEARS AND ROTOR 



(1) Starter gear 

(2) Starter neutral gear 1 

(3) Starter neutral gear 2 

(4) Starter gear 

(5) Starter dutch 

(6) Rotor (A.C. generator 



S 




10Nm(1.0 m*kg,7.2fHb) 



re.-.. . A 








150 Nm (15.0 m-kg, 110 ft'tb) 



>r J30 Nm (3.0 m-kg, 22 ft« 



lb) 



ENGINE ASSEMBLY AND SETTING 



ENG %m 






w 



**&?&&#)* 




1. Install: 

• Timing chain (1) 

♦ Chain guide (2) 




Bolt (chain guide): 
10Nm(1.0mkg) 



NOTE: _ 

Fasten a safety wire (3) to the timing chain to 
prevent it from falling into crankcase, 

2. Apply: 

• Lithium soap base grease 
(onto bearing on starter drives) 



3. Install: 

• Washer (1) 

• Needle bearing (2) 

• Wheel gear (3) 

4. Install; 

• Woodruff key (1) 

• Rotor (2) 

NOTE: 



When installing the magneto rotor, make sure thet 
the woodruff key is properly seated in the keyway of 
the crankshaft. 



5. Install; 

• Nut (1) (rotor) 




Nut (rotor): 
150 Nm (15.0 mkg) 



NOTE: 

Tighten the nut (rotor) while holding the rotor with 
the rotor holder (2). 



p 



Rotor holder: 
P/N YS-01880, 90890-01701 



CAUTION: 



Do not allow the rotor holder to touch the 
projections (3) on the rotor. 



4-75 



4-76 



m CI 




ENGINE ASSEMBLY AND SETTING 



Install: 

• Starter idle gear 2 (1) 

• Needle bearing (2) 

• Shaft (3) 

• Gasket (4) (crankcase cover) 

• Dowel pins (5) 

• O-rings (6) 








7. Install: 

• Crankcase cover (1 ) (left) 




A 



Bolt (crankcase cover): 
10Nm(1.0mkg) 



NOTE: ™____^ 

Tighten the bolts (crankcase cover) in a crisscross 
pattern. 

8. Connect: 

• Neutral switch {2) 

9. Install: 

• Shaft (t) (starter idle gear) 

• Needle bearing (2) 

• Starter idle gear (3} 

• Gasket (4) 

• Dowel pin (5) 



10. Install: 

• Cover (1) 



\ 




Bolt (cover): 
10Nm(1.0mkg) 



ENGINE ASSEMBLY AND SETTING 



ENG 


%m 



CYLINDER 


(1) 


Cylinder head gasket 


(2) 


Cylinder 


(3) 


O-fing 


(4) 


Cylinder gasket 


(5) 


Dowel pin 



TIGHTENING SEQUENCE: 




B 



BORE SIZE: 

100.005-T00.045 mm (3.9372-3.9388 in) 
<LIMIT>: 
<100.1 mm (3.941 in)> 



PISTON-TO-CYLINDER CLEARANCE: 
0.005-0.070 mm (0.0020-0.0028 in) 
<LIMIT>: 
<0.15 mm (0.0059 in)> 



42 Nm (4.2 nrkg, 30 fMb) 



10Nm(1.0nrkg, 7.2 fMb) 



D USE NEW ONE 



38 Nm (3.8 nrkg, 27 ft* lb) 




D USE NEW ONE 



' 



4-77 



4-78 



ENGINE ASSEMBLY AND SETTING 





CYLINDER HEAD 


(D 


Cylinder head cover 


(2) 


Tappet cover 




(intake) 


(3) 


O-ring 


(4) 


Tappet cover (exhaust) 


(5) 


O-ring 


(6) 


Cap 



(7) Cylinder head 

(8) Valve guide 
(intake valve) 

(9) Valve guide 
(exhaust valve) 

(10) Sparkplug 

(11) Dowel pin 



B 



SPARK PLUG TYPE: 
DPR8EA-9 DPR9EA-9 (NGK) 



SPARK PLUG GAP: 
0.8-0.9 mm (0.031-0.035 in) 



CYLINDER HEAD WARPAGE 
LIMIT: 
0.03 mm (0.0012 in) 



10Nm(1.0m*kg,7.2ft-lb) 



12Nm{1.2 rmkg, 8.7 ft*lb) 



10 Nm 

(LOimkg, 7.2 fWb} 



38 Nm 

(3.8 m«kg, 27 ft-lb) 




17.5 Nm (1.75 m«kg 13 ft*lb)J 



Nm (0.7 m»kg, 5.1 ft»lb)j 



SEALANT (QUICK GASKET)* 
YAMAHA BOND NO. 1215® 



ENGINE ASSEMBLY AND SETTING 



ENG 


%m 



CAMSHAFT AND CAMSHAFT CHAIN 



(1) 


Camshaft 


(9) 


Guide stopper plates 


(2) 


Spring 


(10) 


Guide stopper 


0) 


Decompression lever pin 




(intake) 


W 


Decompression lever 


(11) 


Timing chain 


(5) 


Cam chain sprocket 


(12) 


Guide stopper 


(6) 


Decompression cam 




(exhaust) 


(?) 


Spring 


(13) 


Gasket 


(8) 


Tensioner shaft 


(14) 


Cam chain tenstoner 



SHAFT-TO-CAP CLEARANCE: 
0.020-0.054 mm 
(0.0008-0.0021 in) 



B 




20 Nm (2.0 m*kg, 14 ft-lb) 



20 Nm (2.0 m*kg, 14fWb) 




3 10Nm(1.0m-kg T 7.2fWb) 



CAMSHAFT RUNOUT LIMIT: 
0.03 mm (0.0012 in) 



8 Nm (0.8 m-kg, 5.8 fWb) 



4-79 



4-80 



ENGINE ASSEMBLY AND SETTING 






CYLINDER HEAD, CYLINDER AND PISTON 

1. Apply: 

♦ Engine oil 

(onto piston rings and piston pin) 



2. install; 

• Piston rings 

NOTE: 



Be sure to install ring so thai manufacture marks or 
numbers are located on the top side of the rings, 



ENGINE ASSEMBLY AND SETTING 



ENG 


%m 




5. Position: 

• Top ring 

• 2nd ring 

Offset the piston ring end gaps as shown. 

(1) Top ring end 

(2) Oii ring end (lower) 

(3) Oil ring end (upper) 

(4) 2nd ring end 




6. install: 

• Cylinder (1) 





3. Install: 

• Piston (1) 

• Piston pin (2) 

• Circlips (3) 

NOTE: 



The allow (4) on the piston must point to the front 
of the engine. 

Before installing the circlip, cover the crankcase 
with a clean towei or rag so you will not accidentally 
drop the pin dip and material into the crankcase. 





4. install: 

• Gasket (1) (cylinder) 

• Dowel pins (2) 



NOTE: 

Install the cylinder while compressing the piston 
rings by the hand. 



7. install: 

• Bolts (1) 

• Bolts (2) 




Bolts (1): 

42Nm(4.2mkg) 
Bolts (2): 

10Nm(i.0mkg) 




NOTE: 

Tighten the bolts (1) in a crisscross pattern, 

8. Install: 
• Piped) 




Bolt (pipe): 
10 Nm(1.0mkg) 



4-81 



4-82 




ENGINE ASSEMBLY AND SETTING 



9. install: 

• Gasket (1) (cylinder head) 

• Dowel pins (2) 





ENGINE ASSEMBLY AND SETTING 



ENG 


%» 








-x* t "& 





10. Install: 

• Cylinder head (1 



11. Install: 

Bolts (1) 
Bolt (2) 

Bolts (3) 
O-ring (pipe (4) 
Pipe (4) 




Bolts (1), (3): 

38Nm(3.8mkg) 
Bolt (2): 

10Nm(1.0mkg) 



NOTE: ^^__™______^__ 

• Apply the engine oif onto the O-ring. 

• Tighten the bolts (1 ) in a crisscross pattern. 







12. install: 

♦ Chain guide (1) (exhaust) 




13. install: 

♦ Cam sprocket (1) 

• Camshaft (2) 



Installing steps: 

• Turn the crankshaft counterclockwise until the 
IDC mark (3) is aligned whit the stationary 
pointer (4). 

• Align the maich mark on the camshaft with the 
punched mark on the decompression lever. 

• Fit the timing chain onto cam sprocket and install 
the cam sprocket on (he camshaft. 



NOTE: 



When installing the cam sprocket, keep the timing 
chain as tense as possible on the exhaust side. 
Align the pins (7) on the decompression lever 
with the slots (8) in the decompression cam. 
Set the respective match marks (9) to be parallel 
with the case surface on thecorresponding sides, 
and align the respective match marks (10) to be 
vertical 



CAUTION: 



Do not turn crankshaft during the camshaft 
installation. Damage or improper valve timing 
will result. 

• While holding the camshaft, temporary tighten 
the bolts. 



14. Install: 

• Chain tensioner (1) 



4-83 



4-84 




ENGINE ASSEMBLY AND SETTING 



ENG 


%m 




m 



r* 





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w 



st 



Installing steps: 

• Remove the cap bolt (2), washer (3) and spring 

(4>- 

• Release the ratchet (5) and push the tension rod 

(6). 

• Install the chain tensioner with the ratchet end 
facing downward. 

• Tighten the bolts. 




\ 



Bolt {chain tensioner): 
10 Nm (1.0 mkg) 



Install the spring (4), washer (3) and cap bolt 
(2)- 




Cap bolt (timing chain tensioner); 

20 Nm (2.0 mkg) 



ENGINE ASSEMBLY AND SETTING 





ENG 


%m 



18. Apply: 

• Sealant (1) 

(onto the cylinder head mating surfaces) 




Seatant (quick gasket)*: 
PfU. ACC-11001-01 

Yamaha Bond N° 1215*: 
P/N. 90890-85505 



19. install: 

* Dowel pins (2) 
20- Install: 

♦ Cylinder head cover (1 ) 

NOTE: 



Tighten the bolts in stage, using a crisscross pattern. 




Bolt (cylinder head cover): 
10 Nm (1.0 mkg) 




15. Tighten: 

• Bolts (1) (cam sprocket) 




Bolts (cam sprocket): 

20 Nm (2.0 mkg) 




21. Install: 

• Timing plug (1) 

♦ Plug (2) 



16. 



Check: 

• Valve timing 

Out o/ alignment -» Adjust. 

Refer to above steps 13 ~ 15, 



17. 



Check: 

• Valve clearance 

Out of specification -* Adjust. 

Refer to "VALVE CLEARANCE 

ADJUSTMENT* section in CHAPTER 3*. 




Intake valve (cold): 
0.10-0.15 mm 

Exhaust valve (cold): 
0.15-0.20 mm 




Mm 




22. Install: 
• Cap (1) 




Bolt (cylinder head cap): 
10Nm(1.0mkg) 



23. Install: 

• Intake manifolds (1) 




Bolt {intake manifold): 
10 Nm{1.0 mkg) 



4-85 



4-86 




ENGINE ASSEMBLY AND SETTING 



24. Install: 

♦ Sparkplug (1) 





ENGINE ASSEMBLY AND SETTING 



ENG 


%m 






Spark plug: 
18 Nm{1.8 mkg) 



PIPES AND HOSES 

1. Apply: 

• Lithium soap base grease 
(onto O-rings on oil pipes) 



2. Install: 

• Coolant hose (1) 



3. Install: 

• Breather hose {1 ) (crankcase) 

• Oil hose (3) 



Bolts (oil hose): 
10 Nm (1.0 mkg) 







5. install: 

• Starter motor (1) 




Bolt (starter motor): 
10 Nm (1.0 mkg) 



6. Install: 

♦ Oil pipe (1) 




Union bolt (oil pipe): 
20 Nm (2.0 mkg) 

Bolt: 
10 Nm (1.0 mkg) 



7. Install: 

♦ Oil pipe (1) 




Union bolt (oil pipe): 
20 Nm {2.0 mkg) 




SSS-%»* 



4. Apply: 

• Lithium soap base grease 
(onto O-ring on starter motor) 



4-87 



4-88 



ENGINE ASSEMBLY AND SETTING 



ENG 


%m 




ENGINE REASSEMBLY 

When reassembling the engine, reverse the removal 

procedure- Note the following points. 



NOTE: „_ 

Install the bolts and nuts first, and then tighten the 
bolts and nuts to specifications. 



65 Nm (6.5 mkg) 



65 Nm (6.5 mkg) 



10 Nm (1.0 mkg) 



65 Nm {6.5 mkg) 




<*..' i 



/ / 

t llONm(f.Omkg) 



35 Nm (3-5 mkg} 



35 Nm (3.5 mkg) 



10 Nm (1.0 mkg) 



65 Nm (6.5 mkg) 



65 Nm (6.5 mkg)] 




ENGINE ASSEMBLY AND SETTING 



ENG 


@1 P 






1. Remove: 

• Tappet cover (1) (intake) 

• Air bleed screw (2) (oil filter cover) 

2. Apply: 

• 4-stroke engine oil 

(to the camshaft upper side and into the oil 
filter chamber) 



A WARNING 



Apply a liberal amount of 4-stroke engine oil to 
the oil passage in the crankcase, or the engine 
may be damaged. 




Oil quantity: 
Camshaft: 

0.1 L 
Oil filter chamber: 

0.06 L 



3. Install: 

» Tappet cover (intake) 

• Air bleed screw (oil filter cover) 




Bolt {tapped cover): 
10 Nm (1.0 mkg) 

Air bleed screw: 

5 Nm (0.5 mkg) 



4. Install: 

• Drive sprocket (1) 

• Lock washer (2) 

• Nut (3) 




\ 



Nut (drive sprocket): 
110 Nm (11.0 mkg) 



5. Bend: 

* Lock washer tab 
(along nut flat) 



6. 



Adjust: 

• Drive chain slack 

Refer to the "DRIVE CHAIN SLACK 
ADJUSTMENr section in CHAPTER 3°. 




^ 



Drive chain slack: 
25 -40 mm 



4-89 



4-90 



ENGINE ASSEMBLY AND SETTING 

7- install: 

• Sprocket cover 







Screw (sprocket cover): 
10 Nm(1.0 mkg) 



8. install: 

• Shift pedal 




Bolt (shift pedal): 

10 Nm (1.0 mkg) 



9. Connect: 

• Ground lead (1) 

Refer to the "CABLE ROUTING" section 
in CHAPTER 2°. 




Nut (ground lead): 
10 Nm (1.0 mkg) 



10. Adjust: 

• Clutch cable free play 

Refer to the "CLUTCH ADJUSTMENT" 

section in CHAPTER 3°. 



Free play: 
10 - 15 mm 
at clutch lever end 




11. install: 

• Carburetor (to intake manifolds) 




Screw (carburetor joint 
clamp-left): 

2 Nm (0.2 mkg) 
Screw (carburetor joint 

clamp-right): 

5 Nm (0.5 mkg) 



12. Connect: 

• Air cleaner joints to carburetors 



ENGINE ASSEMBLY AND SETTING 



ENG 


%m 



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Screw (carburetor manifold 
clamp-left): 

2 Nm (0.2 mkg) 
Screw (carburetor manifold 
clamp-right): 

5 Nm (0.5 mkg) 



13. Install: 

• Exhaust pipe (1) 

• Muffler (2) 



\ 


Nuts (3) (exhaust pipe); 


10 Nm (1.0 mkg) 

Muffler mounting bolts (4): 






40 Nm (4.0 mkg) 




Bolt (5): 




23 Nm (2.3 mkg) 




Bolt (6) (clamp): 




10 Nm (1.0 mkg) 



14. Install: 
• Radiator 




Boft (radiator): 

10 Nm (1.0 mkg) 



15. Connect: 

* Battery cables 

CAUTION: 



Connect first the positive {+) cable, then the 
negative (~) cable. 



16- Fill: 



Radiator 

Coolant reservoir tank 

See the section "COOLANT CHANGE" in 

CHAPTER 3°. 



17. install: 

• Fuel tank 

• Seat 

• Cowling 

Seethe sections "SEAT, FUELTANK AND 
REAR COWLING* and "COWLING" in 
CHAPTER 3°. 



4-91 



4-92 



CHAPTER 5 



O 




COOLING SYSTEM 



COOLING SYSTEM G-14 

RADIATOR G-15 

JOB INSTRUCTION CHART G-15 

INSPECTION G-16 

ASSEMBLY G-16 

WATER PUMP H-1 

JOB INSTRUCTION CHART H-1 

REMOVAL H-1 

INSPECTION H-2 

ASSEMBLY H-2 

THERMOSTAT H-2 

JOB INSTRUCTION CHART H-2 

REMOVAL H-3 

INSPECTION H-3 

ASSEMBLY H-3 



COOLING SYSTEM 




G-14 



COOLING SYSTEM 



10Nm(1.0 mkg) 



10 Nm {1.0 mkg) 



10 Nm {1.0 mkg) 




10Nm(l.o 



COOLING SYSTEM 




(1) 


Radiator cap 


(15) 


Pipe 


(2) 


Conduction 


(16) 


Hose (from thermostat 


(3) 


Tank level pipe 




cover to pipe) 


(4) 


Overflow pipe 


(17) 


Flower assembly 


(5) 


Tank cap 


(18) 


Radiator 


(6) 


Recovery tank 


(19) 


Hose {from radiator to 


(7) 


Hose (from cylinder 




water pump) 




head) 


(20) 


Hose (from water pump 


(8) 


Pipe (cylinder head) 




to cylinder) 


(9) 


Hose (Irom radiator to 


(21) 


Water pump assembly 




thermostat assembly) 


(22) 


O-ring 


(10) 


Thermostat housing 


(23) 


Dowel pin 


(11) 


Hose (from conduction to 


(24) 


Circlip 




thermostat assembly) 


(25) 


O-ring 


(12) 


Thermostat 


(26) 


Impeller shaft gear 


(13) 


O-ring 


(27) 


Drain bolt 


(14) 


Thermostat cover 


(28) 


Gasket 



COOLANT AND WATER MIXED 

RATIO: 50%-50% 

TOTAL AMOUNT OF LIQUID INTO 

THE CIRCUIT: 1 .4 L 

RESERVOIR TANK CAPACITY: 

0.55 L 



5-1 



5-2 



RADIATOR 



COOL 




RADIATOR 



RADIATOR 





JOB INSTRUCTION CHART 



Order 


Job name/Part name 


Q.ty 


Remarks 




Removal of radiator 




Remove the parts in the order. 

NOTE:. 

When removing the radiator, drain off the 
cooling circuit. 

See the section "COOLANT CHANGE" in 
chapter 3°. 


1 

2 
3 
4 
5 


Clamp 

Hose (detach from radiator) 

Screw 
Screw 
Radiator (disconnect the connector) 


a 

2 

1 
2 
1 


NOTE: 

To approach the radiator, remove side panels 
of cowling. See the section "COWLING" in 
chapter 3°. 


Reverse the removal procedure for instal- 
lation. 








NOTF! 

After installing the radiator, fill the cooling 
system with the specified coolant. 
See the section "COOLANT CHANGE" in 
chapter 3° 





A WARNING 



Do not remove the radiator cap when the engine 
and radiator are hot Scalding hot fluid and 
steam maybe blown out underpressure, which 
could cause serious injury. When open the 
radiator cap, note the following points. Wait 
until the engine has cooled. Place the thick rag 
like a towel over the radiator cap and slowly 
rotate the cap counterclockwise to the detent. 
This procedure allows any residual pressure to 
escape. When the hissing sound has stopped, 
press down on the cap while turning 
counterclockwise and remove it. 



5-3 



5-4 







«/ 





RADIATOR 




INSPECTION 



1 



Inspect: 

• Radiator 

Obstruction ** Blow out with compressed 
air through the rear of the radiator 
Flattened fins -* Repair. 

• Pipes 
Cracks/Damage ** Replace. 

2. Inspect: 

• Radiator cap 

• Radiator cap opening 

Measurement steps: 

• Attach the radiator cap testerto the radiator 
cap. 

• Check the opening pressure of radiator 
cap valve. 




Radiator cap tester: 

P/N YU-24460-1, 90890-01325 
Adapter: 

P/N YU-33984, 90890-01352 



G-16 



RADIATOR 




ASSEMBLY 

Perform disassembling operations in reverse order. 
Pay attention to the following points. 
1. Tighten: 

• Radiator bolts 

• Drain bolts 




A 



Bolts (radiator and drain): 
10Nm(1.Omkg) 



NOTE: __ 

Replace copper seal gasket every time bolts are 

removed. 



2, Fill; 



Cooling circuit with prescribed coolant 
See the section "COOLANT CHANGE" in 

chapter 3°. 



3. Inspect: 

• Cooling system for leakage 



Radiator cap vaive opens at a pressure 

below the specified pressure -» Replace. 



Cap vafve opening pressure: 

95-125 kPa 

(0.95-1.25 kg/cm 2 , 13.57-17.77 psi) 



Measurement steps: 

• Attach the radiator cap tester to the radiator cap. 

• Apply a pressure of 1.0 kg/cm 2 {14.24 psi). 

• Check pressure seal. 

Pressure drop (Leakage) -> Repair. 




Radiator cap tester: 

P/N YU-24460-1, 90890-01325 
Adapter: 

P/N YU-33984, 90890-01352 



5-5 



5-6 



WATER PUMP 





WATER PUMP 




WATER PUMP 




JOB INSTRUCTION CHART 



Order 


Job name/Part name 


Q.ty 


Remarks 




Removal of water pump 




Removal the parts in the order. 

NHTF- 


1 
2 
3 


Clamp 

Hose (detach from pump) 

Screw 


2 
2 
5 


When removing the water pump, drain off Ihe 
cooling circuit. See the section "COOLANT 
CHANGE" in chapter 3°. 




4 


Cover 


1 




5 


Water pump housing 


1 


Reverse the removal procedure for 
installation. 

NOTE: 

After installing the water pump, fill the cooling 
circuit with specified coofant. 
See the section "COOLANT CHANGE" in 
chapter 3°. 






« 



" <D 



7) 



a 



m 



a 



REMOVAL 

1 . Remove: 

• Crrclip (1) 

• Impeller shaft gear (2) 

• Dowel pin (3) 

• Circlip (4) 

• Water pump housing (5) 

• Impeller shaft (6) 



(T 




2. Eliminate: 
• Fur deposits 

From impeller shaft (1) and water pump 
housing (2) 



5-7 



5-8 




y 








■r— 



*£*<*■ 



WATER PUMP 





INSPECTION 

1. Check: 

• O-ring (1) 

• Water pump housing (2) 

• Impeller shaft gear (3) 
Cracks/Wear/Damage -» Replace. 



ASSEMBLY 

Performance "DISASSEMBLY" operations 
reverse order. 
1 . Apply: 

• Molybdenum disulfide grease 
(to the impeller shaft tip) 



in 



THERMOSTAT 




THERMOSTAT 




JOB INSTRUCTION CHART 



Order 



1 
2 

3 

4 

5 
6 
7 



Job name/Part name 



Removal of thermostat 



Screw 

Screw 

Clamp 

Hose (detach) 

Clip 

Hose 

Thermostat assembly with radiator 

cap assembly 



Q.ty 



1 
1 

2 
2 

1 
1 
1 



Remarks 



Remove the parts in the order. 
NOTE; 



When removing the thermostat, drain off the 
cooling circuit. See the section "COOLANT 
CHANGE" in chapter 3°. 



NOTE: - 

To approach the thermostat assembly, 
remove side panel (R) of cowling. See the 
section "COWLING* in chapter 3°. 



Reverse the removal procedure for 
installation. 



NOTE: — 

After installing thermostat, fill the coofing 
system with the specified coolant. 
See the section "COOLANT CHANGE" in 
chapter 3°. 



5-9 



5-10 




95°C (203"F) 
80-84"C 

(176~183°F) 



1 

— 2 



— 3 




64 i 4 



A 



8 mm (0.31 in) 



B 



1 



82°±2°C 
(180°±3.6"F) 



95°C 
(203°F) 



THERMOSTAT 



DISASSEMBLY 

1. Remove: 

• Screws (1) (mounting the cover) 

• Cover (2) 

• O-ring {3} 

• Thermostatic valve (5) from housing (4) 



INSPECTION 

1. Inspect: 

• Thermostatic valve (5) 

Valve does not open at 80°C~84°C 
(176~183°F)^ Replace. 



Inspection steps: 

• Suspend the thermostatic valve in a vessel. 

• Place a reliable thermometer in water. 

• Slowly heat (he water, 

• Observe the thermometer, while continually 
stirring the water . 



(1) Thermometer 

(2) Full opening temperature 

(3) Start opening 

(4) Water 

(5) Thermostatic valve 

(6) Vessel 

[A] FULL OPENING 

[B] CLOSE 



THERMOSTAT 




ASSEMBLY 

Performance "REMOVAL" operations in reverse 
order. 

1. Install: 

• Thermostat (into housing) 

• O-ring 

• Thermostat cover 

2. Tighten: 

• Screws (cover) 




Screws (housing cover): 
10Nm{1.0mkg) 



NOTE: ___^__ 

The thermostatic vaive is sealed and its setting 
requires specialized work. If its accuracy is in 
doubt, replace it. A faulty unit could cause serious 
overheating or over-coo!ing. 



2. Inspect: 

• O-ring 

Wear/Damage -> Replace. 



5-11 



5-12 




CHAPTER 6 



O 



CARBURETOR 



CARBURETOR H-6 

TECHNICAL SPECIFICATIONS/TIGHTENING TORQUES/ EXPLODED VIEW H-6 

SECTION VIEW H-6 

REMOVAL H-7 

DISASSEMBLY H-8 

INSPECTION H-9 

ASSEMBLY H-10 

INSTALLATION H-13 

FUEL LEVEL ADJUSTMENT H-13 

FUEL PUMP H-14 

CHECKING THE PUMP OPERATION H-14 

REMOVAL H-14 

INSPECTION H-14 

INSTALLATION H-14 



CARBURETOR 




H-6 



CARBURETOR 



CARBURETOR 

TYPE: Y26 PV-3J 
MANUFACTURER: 

TBKEI 

1. Carburettor assy 

2. Cover gasket 

3. Gasket, nozzle 

4. Float 

5. Float pin 

6. Float chamber gasket 

7. Screw 

8. Float chamber 
fastening screw 

9. Washer, spring 



10. 
11. 
12. 
13. 

14. 



Hose 

Spacer 
Screw 
Gasket 
Throttle valve 
spring 

15. Washer spring 

16. Nut 
Gasket 
Screw 
Lock screw 
Nut 

Float chamber 
drain screw 
Hoses 



17. 
18. 
19. 
20- 
21. 



22. 



23. Diaphragm 

24. Cover 

25. Connecter comp. 

26. Washer 

27. Washer spring 

28. Spring 

29. Bolt 

30. Hose 

31. Hose 

32. Screw 

33. Screw 

34 . Hose 

35. Clamp 

36. Main jet (FIRST) 

37. Needle jet 1 



38. Throttle valve 1 

39. Pilot jet 

40. Main jet (SEC.) 

41. Needle jet 2 

42. Pilot adjuster 

43. Needle valve set 
(jet needle) 

44. Stop screw knob 

45. Throttle screw set 
46- Diaphragm (1) 

47. Needle jet 

48- Needle jet 

49. Starter set 

50. Bracket, gas lever 

51. Air intake hose 





SECTION VIEW 

(1 ) Needle jet (primary) 

(2) Valve housing 

(3) Needle valve 

(4) Main nipple (primary) 

(5) Main jet (primary) 

(6) Pilot air screw 

(7) Needie jet (secondary) 



(8) Main nipple (secondary) 

(9) Main jet (secondary) 

[A] Primary carburetor 

[B] Secondary carburetor 



C^ 



Air 

Fuel 

Mixture 




6-1 



6-2 



CARBURETOR 




H-7 



REMOVAL 




CARBURETOR 




JOB INSTRUCTION CHART 



Order 


Job name/Part name 


Q.ty 


Remarks 




Removal of carburetors 




Remove the parts in the order. 

NOTE: 

To approach the carburetors, remove seat 
and fuel tank- 
See the section "SEAT, FUEL TANK AND 


1 


Ciamp (air cleaner joint) 


2 


REAR COWLING" in chapter 3°. 




2 


Air cleaner case 


1 




3 


Panel 


1 




4 


Lock nut (loosen) 


4 




5 


Throttle control cable (disconnect) 


2 




6 


Screw (starter knob) 


1 




7 


Screw (idle speed knob) 


1 




8 


Clamp (intake manifold) 


2 




9 


Carburetor 


2 


Reverse the removal procedure for 
installation. 



6-3 



6-4 






CARBURETOR 




H-8 



DISASSEMBLY 



NOTE: 



The following parts must be cleaned and examined 
without removing the carburetor from the engine. 

• Diaphragm (enrichment) 

• Starter control unit 

• Throttle lock screw 

• Idle speed screw 



2. 



Detach: 

• Air ventilation pipe {1 

• Suction pipe (2) 

• Air ventilation pipe (3) 

• Overflow hose (4) 
Remove: 

• Support plate (5) (front) 

• Support plate (6) (rear) 



3. 



Detach: 

• Pipe (1) 

• Pipe (2) 

• Connecting bracket (3) 
Separate: 

• Primary carburetor (4) 

• Secondary carburetor (5) 



CARBURETOR 




^Ife^ 2 


*<2|||r 3 


V I 1 ^^V"* 




V 




t 







Primary carburetor 

1. Remove: 

• Float chamber (1) 

• Float pin (2) 

• Float (3) 



NOTE: 

Remove the float needle in the direction of the 
arrow. 



2. 



Remove: 

Needle valve/Valve housing (1) 
Main jet {FIRST)/Needte jet (2) 

Pilot jet (3) 

Idle speed screw (4) 
O-ring (5) 



3. 



4, 



Disconnect: 

• Throttle stop knob {1 ) 
Remove: 

• Starter cylinder (2) (from starter cable) 



5. 



Remove: 

• Cover (1) (enrichment) 

• Spring (2) 

• Diaphragm (3) 



S> 



6-5 



6-6 




tK?\ * 



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CARBURETOR 




H-9 



6. Remove: 

• Top cover (1) 

• Gasket (2) 

• Screw (3) (connecter comp.) 



7. 



Remove: 

• Throttle lever (1 

• Roller (2) 

• Cable support (3) 



8. 



Remove: 

♦ Throttle shaft (1 

# Spring (2) 

• Throttle valve (with connecter camp. 



9. 



Remove: 

♦ Connecter comp. 

♦ Needle jet (2) 

♦ Throttle valve (3) 



1) 



Secondary carburetor 

1. Remove: 

• Plug(1) 

• Gasket (2) 

• Main jet (SEC.) (3) 

• Needle jet 2 (4) 





CARBURETOR 





2. Remove: 

• Top cover (1) 

• Spring (2) 




3. Remove: 

• Piston valve (1) 

• Needle jet (2) 




INSPECTION 

1 . Inspect: 

• Carburetor body 

Soiled ■* Clean. 

• Float chamber 

Cracks/Damage -* Replace. 

• Fuel passages 
Obstructed -# Clean. 

NOTE: 

Use petroleum-based solutions to clean carburetor 
body (never use caustic solution). Clean all 
passages and jets with compressed air, 

2. Inspect: 

• Valve housing (1) 

• Needle valve (2) 
Wear/Corrosion -> Replace. 

• O-Ring (3) 
Damaged -> Replace. 

NOTE: - 

Always replace the needle valve and the valve 
housing together. 



3. Inspect: 

• Throttle lock knob (1) 
Damaged -* Replace. 

• Starter cylinder (2) 
Wear/Damage -> Replace. 



6-7 



6-8 



CARBURETOR 




s" 




4. Inspect: 

• Diaphragm (1) (piston valve) 

• Diaphragm (2) (enrichment) 
Damaged -» Replace. 




5. Inspect: 

• Needfe jet (1 ) (primary) 

• Needle jet (2) (secondary) 
Curvature/Wear/ 
Damage -* Replace. 





6. Inspect: 

♦ Throttle valve (1 ) (primary) 

• Piston valve (2) (secondary) 
Wear/Damaged -> Replace. 



m 





7. Check: 

• Free movement 

Hampered -> Replace. 
Fit the throttle valve and piston valve into 
the carburetor body and check that 
movement is free, 

[A] Primary carburetor 

[B] Secondary carburetor 



8. Inspect: 
• Float (1) 

Damaged -> Replace. 



6-9 





CARBURETOR 




9. Inspect: 

Main jet (1) (primary) 
Main jet (2) (secondary) 
Needle jet 1 (3) (primary) 
Needle jet 2 (4) (secondary) 
O-ring (5) (needle jet 1) 
Piiot jet (6) 

NOTE: 

Clean jets with compressed air. 



ASSEMBLY 

Perform "DISASSEMBLY" operations in reverse 
order. Pay attention to the following points. 

CAUTION; 



Wash all parts with clean petrol prior to 
reassembly. * 

Always use new gaskets. 





Secondary carburetor 

1. Install: 

♦ Needle jet (1) 

• Piston valve (2) 

NOTE: 



Draw the diaphragm tab level with the notch on the 
secondary carburetor. 



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JJj 




U"" 






m$$y 



2. Install: 

♦ Spring (1) 

• Top cover (2) 




Screw (top cover): 
2 Nm (0.2 mkg) 



s£% 


\ 

t 


\ - 1 


T^' 


$ 2 

m 

Sr 3 



3. install: 

• Needle jet 2(1) 

• Main jet (2) (secondary) 

• Plug (3) 




Main jet: 
2 Nm (0.2 mkg) 

Pfug: 
9 Nm (0.9 mkg) 



6-10 



CARBURETOR 




"> 
*->" 




Primary carburetor 

1. Install: 

• Needle jet (1) 

• Connecter comp. (2) (lo throttle valve) 




\ 



Screw (connecter comp); 
0,8 Nm (0.08 mkg) 




NOTE: 

Check that the connecter unit (3) is in the position 
shown in the figure. 




2. install: 

• Throttle valve (1) 





3. Install: 

• Spring {1 

• Throttle shaft (2) 

NOTE: 



Assemble the spring as shown in the illustration. 



4. Install: 

• Screw (1) (connecter comp.) 

NOTE: 



Turn the thrust shaft clockwise (1/2 turn) to preload 
the spring and Ihen, holding it in position, tighten the 
screw (connecter comp.). 




Screw (connecter comp.): 
2 Nm (0.2 mkg) 



6-11 






m- 







8fe- -w 



CARBURETOR 




5. Install: 

• Cable support (1) 

• Roller (2) 

• Throttle lever (3) 

NOTE: 

Check that the throttle shaft lever (4) and the 
adjuster bolt (5) are aligned when tightening the 
throttle lever nut (6). 




Screw (cable support): 

3 Nm (Q.3 mkg) 
Nut (throttle lever): 

3.5 Nm (0.35 mkg) 




t:> 



6. Install: 

• Gasket (1) 

• Top cover (2) 




Screw (top cover): 
2 Nm (0.2 mkg) 



•=?■> 




7. Install: 

• Diaphragm (1) (enrichment) 

NOTE: 



Make the diaphragm tab coincide with the gravity 
en richer notch. 



tUm+imm 



Q. Connect: 

♦ Starter cylinder (to starter cable) 




\ 



Starter piston: 
6 Nm (0.6 mkg) 



9. Install: 

• Throttle stop knob 



6-12 



CARBURETOR 







W® *~® 



t ,m v& icar **& u 




^K.J* 



ejbrerre i¥— t* - t - 




10. Install: 

• Throttle stop screw (1 

• Pilot jet (2) 

• Needle jet 1 (3) 

• Main jet (4) (primary) 

• Valve housing (5) 

• Needle valve (6) (with float) 




Needle jet 1 : 
2 Nm (0.2 mkg) 

Main jet (primary): 
1.6 Nm (0.16 mkg) 

Screw (valve housing): 
2 Nm (0.2 mkg) 



11. Install: 

• Float pin (1 

NOTE: 



Assemble the float pin in the opposite direction to 
the arrow. 



12. Measure: 

• Float height (a) 

Out of specification -* Adjust. 




Float height; 

25.0-27.0 mm 



Measurement and adjustment: 

• Hold the carburetor upside down. 

• Measure the distance from the joint plane of the 
float chamber (without the gasket) and the top of 
the float. 




(1) i 



NOTE: „ _ 

The float arm must rest on the neeedle valve 
without being pressed. 

• If the float height is out of tolerance, check the 

valve housing and the needle valve. 

• If either is worn, replace both, 

• If both are perfect, adjust the float height by 
bending the wing tab of the float itself (1), 

• Recheck the float height. 



6-13 



♦w-^ 




CARBURETOR 




13. Install: 

♦ Float chamber 




\ 



Screw {float chamber): 
2 Nm (0.2 mkg) 



14. Adjust: 

• Pilot air screw (1) 



Adjustment: 

• Turn the screw until it is slightly locked 

• Unscrew by specified turns. 




Pilot air screw (unscrew): 
Unscrew3 turns 









\^.1 




\ XL //'/ ~i 6.0 mm 
^J^tr/ % f0.24in) 



15. Install: 

♦ Primary carburetor ( 1 ) 

• Secondary carburetor <2) 

16, Install: 

• Support plate (front) (1) 

# Support piate (rear) (2) 




* 



Screw (support plate): 
3 Nm (0.3 mkg) 



NOTE: 

After screwing the plates, check that the throttle 
lever and throttle valve work properly and without 
sticking. 

17. Connect: 

• Overflow hose (3) 

• Air ventilation pipe (4) 

• Air ventilation pipe (5) 

• Suction pipe (6) 
18- Adjust: 

• Synchronisation of secondary carburetor 



» < * * t t 



***** * * * * 



********* 



Adjustment: 

• Move the primary throttle valve (t) to a height of 
6.0 mm as shown in the figure. 



6-14 



CARBURETOR 







Tighten or loosen the synchronisation screw (1) 
until the secondary throttle valve (2) starts to 
open. 



Check that the secondary valve \s open 
horizontally (a)=(b) when the primary carburetor 
valve is completely open. 



CARBURETOR 




4. Adjust: 

• Throttle cable free play 

See section THROTTLE CABLE FREE 
PLAY ADJUSTMENT in CHAPTER 3°. 




s 



Throttle cable free play: 
3-5 mm 



5. Adjust: 

• idle speed 

See sectionlDLE SPEED ADJUSTMENT 
in CHAPTER 3°. 



C\ 



Engine idle speed: 
1 ,300 ± 50 rpm 




INSTALLATION 

Perform the "REMOVAL" procedures in reverse 
order, paying attention to the following points: 

1. Install: 

♦ Carburetor unit 





Screw (clamp-left joint): 
2 Nm (0.2 mkg) 

Screw (clamp-right joint); 
5 Nm (0.5 mkg) 



2. Install: 

• The air cleaner hose to the carburetor 
moving the air filter case towards the front 
part 



Screw (clamp-left manifold): 
2 Nm (0.2 mkg) 

Screw (clamp-right manifold): 

5 Nm (0.5 mkg) 



3. Install: 

• Throttle cable (1) 

• Starter cable knob (2) 




FUEL LEVEL ADJUSTMENT 

1 . Place the motorcycle on a level surface. 

2. Make sure that the carburetor is in a horizontal 
position by placing a jack under the engine. 



3. Connect the fuel level gauge (1) to the drain 
pipe of the float chamber. 




Fuel level gauge: 
P/N.YM-01312-A 

P/N. 90890-01312 



4. Loosen drainer screw (2) and heat the 
engine. 

5. Make sure that fuel level gauge is in a vertical 
position near the match face of the float 
chamber. 

6. Measure; 

• Fuel level (a) 

Out of specification -> Adjust. 




Fuel level: 

6.0~8.0 mm 
Under the edge of the match face 
of the float chamber 



6-15 



6-16 



CARBURETOR/FUEL PUMP 




<i>H 





7. Adjust; 

♦ Fuel level 



Fuel level adjustment: 

♦ Remove carburetor unit. 

• Inspect vafve housing and needle valve. 
If either of the two is worn, replace both. 

♦ If both are perfect, adjust float height by bending 
the wing tab of the float itself (1). 

• Recheck the fuel level. 



FUEL PUMP 

CHECKING THE PUMP OPERATION 

1 . Inspect: 

• Fuel pump operation 



**■******«#■*■* 



* ft 



Checking the operation: 

• Disconnect the carburetor fuel delivery pipe (1). 

• Place a container under the tip ol the delivery 
pipe. 

• Turn the main switch to "ON". 

• Press the start button. 

• Check that the fuel comes out of the delivery 
pipe. If the fuel does not come out. replace the 
fuel pump unit. 

Refer to the "iNSPECTION" section. 



REMOVAL 

1. Remove: 

• Seat 

• Fuel tank. See the section "SEAT, FUEL 

TANK AND REAR COWLING* in chapter 
3°. 

2. Disconnect: 

• Fuel delivery pipe (1) (to carburetor) 

• Suction pipe (2) 

« Fuel delivery pipe (3) (from fuel cock to 
pump) 

3. Remove: 

• Nuts (4) (fuef pump) 

• Fuel pump assembly (5) 




FUEL PUMP 




INSPECTION 

1 . Inspect: 

• Fue! pipes 

• Suction pipe 

• Cracks/Wear/Damage 



Replace. 



2. Inspect: 

• Fuel pump assembly (1) 
Cracks/Damage -> Replace. 



INSTALLATION 

Perform the "REMOVAL" procedures in reverse 

order, paying attention to the following points, 

1. Connect: 

• Suction pipe 

* Fuel delivery pipe to carburetor 

♦ Fuel pipe (from fuel cock to pump) 



NOTE: 

When connecting pipes, be carefut to do so 

correctly. 

2. Install: 

• Fuel pump assembly {to fuel tank bracket) 

3. Tighten: 

• Fuel pump assembly mounting nuts 




Nuts (fuel pump to bracket): 
5 Nm (0.5 mkg) 



4. Install: 

• Fuel tank 

• Seat 

See the section "SEAT, FUEL TANK AND 
REAR COWLING" in chapter 3°. 



6-17 



6-18 




CHAPTER 7 



CHASSIS 



o 





REAR SHOCK ABSORBER J-14 

REMOVAL J-14 

NOTE ON DISPOSAL J-15 

INSPECTION J-15 

ADJUSTMENT J-15 



FRONT WHEEL 1-1 

REMOVAL 1-1 

INSPECTION I-2 

STATIC BALANCING I-2 

REAR WHEEL I-3 

REMOVAL I-4 

INSPECTION I-5 

FRONT AND REAR BRAKE I-5 

FRONT MASTER CYLINDER I-5 

FRONT BRAKE CALIPER I-5 

REAR MASTER CYLINDER I-6 

REAR BRAKE CALIPER I-6 

BRAKE PAD REPLACEMENT I-7 

FRONT BRAKE CALIPER DISASSEMBLY I-9 

REAR BRAKE CALIPER DISASSEMBLY 1-10 

FRONT MASTER CYLINDER DISASSEMBLY 1-11 

REAR MASTER CSLINDER DISASSEMBLY 1-12 

INSPECTION AND REPAIR 1-13 

FRONT FORK 1-15 

REMOVAL 1-16 

OIL CHANGE J-1 

CLEANING THE DUST SEAL J-3 

REPLACING THE SEALS AND BUSHES J-4 

ADJUSTMENT J-10 

STEERING J-1 1 

REMOVAL J-1 1 

INSPECTION J-12 

INSTALLATION J-12 



SWING ARM J-16 

REMOVAL K-1 

INSPECTION K-2 

DRIVE CHAIN, SPROCKET AND CROWN K-2 

REMOVAL K-2 

INSPECTION K-3 



FRONT WHEEL 





FRONT WHEEL 




CHASSIS 



REMOVAL 



FRONT WHEEL 

(1) Tyre 

(2) Spacer 

(3) Dust cover 

(4) Bearing 

(5) Cast wheel 

(6) Valve 

(7) Cover (gear unit housing) 

(8) Meter dutch 

(9) Clutch meter retainer 

(10) Gear unit assembly 

(11) Wheel axle 

(12) Wheel axle retainer screw 



(A) WHEEL AXLE TIGHTENING TORQUE: 

70 Nm (7.0 mkg) 
[Bj WHEEL AXLE SCREW TIGHTENING 

TORQUE: 10 Nm {1 .0 mkg) 
TYRE MEASUREMENT AND TYPE: 

110/70 ZR17TX15 MICHELIN - 

110/70 ZR1 7 TLOUNLOP 
RIM MEASUREMENT: 3.00 x 17" 
RUNOUT LIMIT: 

VERTICAL: 0.5 mm 

LATERAL: 0.5 mm 
INFLATION PRESSURE JN bar-kg/cm 2 (psi): 

WITH DRIVER ONLY: 2 (28) 

WITH DRIVER AND PASSENGER: 2.2 (32) 





JOB INSTRUCTION CHART 



Order 


Job name/Part name 


Q.ty 


Remarks 


1 
2 
3 

4 
5 


Removal of front wheel 

Odometer cap (detach) 

Odometer cable 

Axle retainer screw (loosen) 

Wheel axle 

Wheel 




Remove the parts in the order. 


I A WARNING ^■I^^H^^^H 


Support the motorcycle securely so that it 
does not fall over when the wheel is 
removed. 


Reverse the removal procedure for instal- 
lation. 

NOTE: 

Check that the odometer gear unit hits the 

cross on the fork stem and that the odometer 

cable is properly connected. 

Before retightening the wheel axie fastening 

screw to the fork, pump the fork repeatedly. 



7-1 



7-2 



FRONT WHEEL 






INSPECTION 

1. Eliminate any traces of oxidisation from the 
parts. 



2. 



Inspect: 

• Wheel axle 

Turn the axle on a level surface. 

Curvature -» Replace. 



WARNING 



Never attempt to straighten a wheel axle. 



3, 



Inspect; 

• Tyre 

Wear/Damaged -> Replace. 

See section TYRE INSPECTION" in 

CHAPTER 3°. 

• Wheel 
Cracks/Deformation/Curvature -> Replace- 
See section "WHEEL INSPECTION" in 

CHAPTER 3°. 




4. 



Measure: 

♦ Wheel runout 

Out of specification *-> Check the wheel 

and bearing free play- 




Wheel runout limits: 
Vertical (1): 0.5 mm 
Lateral (2): 0.5 mm 



WARNING 



After assembling a tyre, drive slowly to allow it 
to adapt to the rim. If this precaution is not 
observed, damage might be caused to the cycle 
and accidents to the driver. 



FRONT WHEEL 







How to replace wheel bearings and dust covers: 

• Clean the outside of the hub. 

• Remove the dust cover (1) with a flat-headed 
screw driver. 

NOTE: 

Place a rag on the outside to avoid damaging the 

dust cover. 



• Disassemble the bearing (1 ) with a normal puller 
(2). 

• Install the new bearing and the dust cover by 
following the disassembly procedures in reverse 
order. 

NOTE: 

Use a wrench (4) with an external diameter equal to 
that of the bearing and dust cover. 

CAUTION: 

Do not strike the bearing inner race (5) or balls 
(6). The contact must only be made with the 
outer race (7). 



***** 



6. Inspect; 

• Tachometer socket 

Wear/Damage -» Replace. 



5. Inspect: 

* Wheel bearings 

Free play in wheel hub or wheel which 
does not turn smoothly -> Replace. 

• Oil seal 
Wear/Damage -» Replace. 



STATIC BALANCING 



NOTE: 



After replacing the tyre and/or rim, it is necessary 

to balance the wheel. 

Balance the wheel with the brake disk installed. 



7-3 



7-4 



FRONT WHEEL 





REAR WHEEL 





1 . Remove; 

• Balancing weight 

2. Set the wheel on a suitable support 

3. Look for; 

• The heaviest point 

Procedure: 

a. Turn the whee! and wait for it to stop. 

b. Make a mark "X"T on the lowest point of the 
wheel. 

c. Move the mark "X1" to an angle of 90° to the 
starling position. 

d. Let the wheel go and wait until it stops. 
Make a mark "X2" on the lowest point. 

e. Repeat the preceding operations b, c and d 
v various times until the two marks meet. 

f . This point is heavy point U X H . 




4. Carry out: 

• Wheel balancing 



Balancing procedure: 

• Install a balancing weight {1} on the rim at the 

point exactly opposite "X". 

NOTE: 

Start with the lightest weight available. 





Turn the wheel so that the heavy point ends at 
90° to the perpendicular- 
Check that the heavy point does not shift. 
Otherwise, try with another weight until the wheel 
is balanced. 



5. Check: 

• Wheel balancing 

Control procedure: 

• Set the wheel into any of the positions shown in 
the figure. 

• Check that in each of the points the wheel is still. 
Otherwise, balance the wheel once again. 



REAR WHEEL 

(1) Wheel axle 

(2) Flat washer 

(3) Chain stretcher 

(4) Spacer 

(5) Dust cover 

(6) Bearing 

(7) Cast wheel 
{8) Tyre 

(9) Valve 

(10) Damper 

(11) Hub clutch 

(12) Drive chain 

(13) Crown 



A 




(14) Self-locking nut 

(15) Crown mounting screw 

[A] WHEEL AXLE NUT TIGHTENING TORQUE: 
80 Nm (8.0 mkg) 

[B] CROWN SCREW TIGHTENING TORQUE: 
23 Nm (2.3 mkg) 

TYRE MEASUREMENT AND TYPE; 

150/60 ZR17 TX25 MICHELIN - 150/60 ZR17 TL DUNLOP 

RUNOUT LIMIT: 

LATERAL: 0.5 mm 

VERTICAL: 0.5 mm 
INFLATION PRESSURE IN bar-kg/cm 2 (psi) 

WITH DRIVER ONLY: 2.2 (32) 

WITH DRIVER AND PASSENGER; 2.5 (37) 
DRIVE CHAIN SLACK: 25 - 40 mm 




iMW 



7-5 



?~6 



REAR WHEEL 




1-4 



REMOVAL 




REAR WHEEL 




JOB INSTRUCTION CHART 



Order 


Job name/Part name 


Q.ty 


Remarks 


1 

2 
3 
4 

5 
6 

1 


Removal of rear wheel 

Stretcher lock nut (loosen) 

Stretcher (unscrew) 

Wheel axle nut 

Drive chain (remove from crown) 

Wheel axle 

Rear wheel assembly 


2 
2 

1 
1 

1 
1 


Remove the parts in the order. 


1 A WARDING ^^^^H^^^^H 


Support the motorcycle securely so that 
it does not fall over when the wheel Is 
removed. 


NOTF* 


To remove the drive chain from crown push 
the rear wheel forward. 

NOTF- 


The brake caliper bracket must be supported 
when the wheel is removed. 

CAUTION: 


Do not operate the brake pedal when the 
wheel is removed. 


Reverse the removal procedure for 
installation. 

CAUTION: 


Adjust drive chain slack. 

Make sure that the chain stretchers are 

putted in the same position. 



INSPECTION 

1. Inspect: 



Rear wheel 
See section 
TION*. 



"FRONT WHEEL-tNSPEC- 



2. 



3. 



Check; 

• Tyre 

• Wheel 

See section "FRONT WHEEL-INSPEC- 
TION*. 

Measure: 

• Wheel runout 

See section "FRONT WHEEL-INSPEC- 
TION'*. 



4. Check: 

• Dust cover 

• Wheel bearings 

See section "FRONT WHEEL-INSPEC- 
TION'". 

5. Check: 

• Wheel balancing 

See section "FRONT WHEEL-STATIC 
BALANCING". 



7-7 



7-8 



FRONT AND REAR BRAKE 





FRONT AND REAR BRAKE 

FRONT MASTER CYLINDER 

(1) Brake control lever 

(2) Stop light switch 

(3) Handle bar master cylinder fastening bracket 

(4) Brake fluid tank 

(5) Brake hose 



[A] 



PUMPER ASSEMBLY NOT SUPPLIED. 
REPLACE WHOLE MASTER CYLINDER 
UNIT IF NECESSARY. 
REPLACECOPPERSEALGASKETS EVERY 
TIME MASTER CYLINDER IS REMOVED- 
BRAKE FLUID: DOT #4 



[BI 



FRONT AND REAR BRAKE 




FRONT BRAKE CALIPER 

(1) Brake disk 

(2) Brake pad lock pin 

(3) Bleeder screw 

(4) Brake pads 

(5) Pad spring 

(6) Pad pin lock spring 



(7) Brake caliper piston unit 
[A] PISTON GASKETS NOT 
SUPPLIED. 

REPLACE ENTIRE CALIPER 
UNIT, IF NECESSARY. 
BRAKE FLUID; DOT#4 
BRAKE PAD WEAR LIMIT: 
0,8 mm 



BRAKE DISK WEAR LIMIT: 

3.5 mm 

BRAKE DISK RUNOUT LIMIT: 

0.3 mm 

[B]USELOCTITE®242 

MEDIUM THREAD LOCKING 

LIQUID 



10Nm(1.0mkg) 




15Nm(1.5rnkci)] 



50 Nm (5.0 mkg) 



6 Nm (0.6 mkg) 




23 Nm (2.3 mkg) 



7-9 



7-10 









FRONT AND F 










1-6 








FRONT AND F 










^EAR BRAKE 


CHAS 


<$%) 




1EAR BRAKE 


CHAS 


(£% 








REAR MASTER CYLINDER 










REAR BRAKE CALIPER 








(1) 


Brake fluid tank cover 


(7) 


Master cylinder 


[B] REPLACE COPPER SEAL 


0) 


Bleeder screw 


(7) 


Brake disk 


BRAKE FLUID; D0T#4 


(2) 


Diaphragm 


(8) 


Brake pedal 


GASKETS EVERY TIME 


(2) 


Pad spring 


(8) 


Brake caliper cylinder gaskets 


BRAKE PAD WEAR LIMIT: 0.8 mm 


(3) 


Brake fluid tank 


[A] 


PUMPER ASSEMBLY 


MASTER CYLINDER IS 


(3) 


Brake pad lock pin 


0) 


Cylinder 


BRAKE DISK WEAR LIMIT: 4 mm 


(4) 


Hose 




NOT SUPPLIED. RE- 


REMOVED. 


(4) 


Brake pad 


[A] 


CYLINDER GASKETS NOT 


BRAKE DISK RUNOUT LIMIT: 


(5) 


Stop light switch 




PLACE WHOLE MASTER 


BRAKE FLUID: DOT #4 


(5) 


Brake caliper 




SUPPLIED. REPLACE WHOLE 


0.3 mm 


(6) 


Brake hose 




CYLINDER UNIT IF 




(6) 


8rake caliper bracket 




BRAKE CALIPER ASSEMBLY 


[B] USE LOCTITE® 242 MEDIUM 








NECESSARY. 


















IF NECESSARY. 


THREAD LOCKING LIQUID 



4 Nm (0.4 mkg) 



1 



5 Nm (1.5 mkg)] 



15 Nm (1.5 mkg) 



©- . 



13 Nm (1.3 mkg) 




5S£a* 



23 Ni 




^ 



7-11 



7-12 



FRONT AND REAR BRAKE 





CAUTION; 



Brake components rarefy require disassembly. 
DO NOT: 

• Disassemble brake components unless ab- 
solutely necessary. 

• Use solvents on internal brake components. 

• Use brake fluid already used for bleeding. 

• Allow brake fluid to come into contact wilh 
the eyes as it may cause injury. 

• Allow brake fluid to come into contact with 
painted or plastic parts as it may damage 
them. 

• Disconnect any hydraulic connection, other- 
wise the whole system must be disassem- 
bled, drained, cleaned, then properly filled 
and bled after reassembly. 



FRONT AND REAR BRAKE 






3. Remove; 

• Pad spring (3) 

♦ Brake pads (4) 

NOTE: 



If you replace the pads, also replace the spring. 
If one of the two pads has to be replaced because 
it is worn, replace both. 




Wear limit (a); 
0.8 mm 



4, Install: 

♦ Brake pads (new) 

♦ Pad spring (new) 

• Pad fastening pin 

• Pad pin lock spring 



BRAKE PAD REPLACEMENT 




NOTE: 

It is unnecessary to disassemble the brake caliper 
and hose to replace the pads. 



A WARNING 



Support the motorcycle securely to prevent it 
falling over. 

Front brake 

1 . Remove: 

• Pad pin lock spring (1 ) 

2. Remove: 

• Pad fastening pin (2) 

NOTE: - 

To remove the pad fastening pin, strike from the 
inside with punch with a suitable diameter, being 
careful not to damage the pin housing. 




Installation procedure: 

• Connect the hose firmly to the caliper bleeder 
screw (1 ). Place the other end of the hose in an 
open container. 

• Loosen the caliper bleeder screw and push the 
pistons into the caliper with your finger. 

• Retighten the bleeder screw. 




Caliper bleeder screw: 
6 Nm {0.6 mkg) 



Install the (new) brake pads and (new) spring. 
Fit the pad fastening pin (2) well into its housing by 
hammering from the outside with a punch with a 
suitable diameter- 
Install the lock spring (3) into pad fastening pin. 



7*13 



7-14 



/ \ 



A 



FRONT AND REAR BRAKE 




/ v 



\ 




-i 




^M 



\ 



im 



^~<m 



\~ 



V 



V. 

! \ 






*i ; arri££**7 



'IV- ^ 

i. iiVy 

\ V,\v 






> 



; 





5. Check: 

• Level of brake fluid in tank 

See the section "BRAKE FLUID LEVEL 
CHECK" in CHAPTER 3". 

6. Check: 

• Brake fever functioning 

Lever soft and spongy -» Bleed air from 
brake circuit- 
See the section U AIR BLEEDING" in CHAP- 
TER 3 U . 



Rear brake 

1. Remove: 

• Brake pad fastening pin (1) 

NOTE; 



To remove the pad fastening pin, strike from the 
inside with punch with a suitable diameter, being 

careful not to damage the pin housing. 



2. Remove: 

• Pad springs (2) 

• Brake pads (3) 

NOTE: 



if you replace the pads, also replace the spring. 
If either of !he two pads has to be replaced 
because it is worn, replace both. 




Wear limit (a): 
0.8 mm 



FRONT AND REAR BRAKE 





Installation procedure: 

• Connect the hose firmly to the caliper bleeder 
screw (1). Place the other end of the hose in an 

open container. 

• Loosen the caliper bleeder screw and push the 
pistons into the caliper with your finger. 

• Retighten the bleeder screw. 




\ 



Caliper bleeder screw: 
6Nm(0.6mkg) 



Install the (new) spring and (new) brake pads. 
Fit the pad fastening pin (2) well into its housing 
by hammering with a punch with a suitable 
diameter. 



**#***«********#** 



* * 



* * * • 



3. 



4. 



Check: 

♦ Level of brake fluid in tank 

See the section "BRAKE FLUID LEVEL 

CHECK' in CHAPTER 3°. 



Check: 

• Brake pedal functioning 

Pedal soft and pongy -» Bleed air from 
brake circuit. 

Seethesection u AIRBLEEDlNG H inCHAP- 
TER3°. 













z u 


1 


p t 





7-15 



7-16 



FRONT AND REAR BRAKE 





FRONT BRAKE CALIPER DISASSEMBLY 




FRONT AND REAR BRAKE 




JOB INSTRUCTION CHART 



Order 



Job name/Part name 



Removal and disassembling 
of front brake caliper 



1 


Lock spring 


2 


Pad pin 


3 


Spring 


4 


Brake pad 


5 


Screw (fastening the hose) 


6 


Screw 


7 


Screw 


8 


Piston 


9 


Dust seal 


10 


Oil seal 



Q.ty 



1 
1 
1 
2 
1 
2 
4 
4 
4 
4 



Remarks 



Remove the parts in the order. 
NOTE: 



Before disassembling the brake caliperdrain 
off the fluid from the braking circuit- 



WARNING 



Support the motorcycle securely to pre- 
vent It falling over. 

NOTE: 

Blowing compressed air into the hose 
connection, make the piston leave the body 
of the caliper. 



WARNING 



Do not force the piston out with a lever 
or other tools. 

Cover the piston with a rag. Be careful 
to prevent the piston from damaging 
the cylinder as it leaves it. 



Reverse the procedure for assembling 
and installation. 



NOTE: - - 

Aftercompleting the reassembly operations, 
fill brake circuit with prescribed fluid- Bleed 
the air from the circuit See the section "AIR 
BLEEDING* in chapter 3°. 



7-17 



7-18 



FRONT AND REAR BRAKE 





REAR BRAKE CALIPER DISASSEMBLY 



6 Nm(0.6 mkg) 



25 Nm (2.5 mkg) 




FRONT AND REAR BRAKE 




JOB INSTRUCTION CHART 



Order 



1 


Pad ptn 


2 


Spring 


3 


Brake pad 


4 


Screw 


5 


Brake hose 


6 


Screw 


7 


Caliper (unit) 


8 


Screw 


9 


Dust seal 


10 


Piston 


11 


Oil seal 



Job name/Part name 



Removal and disassembly 
of rear brake caliper 



Q.ty 



1 
3 
2 
1 
1 
2 
1 
2 
2 
2 
2 



Remarks 



Remove the parts in the order. 
NOTE: 



Before disassembling the brake caliper drain 

off the fluid from the braking circuit. 



WARNING 



Support the motorcycle securely to pre- 
vent it falling over 

NOTE: 

Blowing compressed air into the hose 
connection, make the piston leave the body 
of the caliper. 



A WARNING 



Do not force the piston out with a lever 
or other tools. 

Cover the piston with a rag. Be careful 
to prevent the piston from damaging 
the cylinder as it leaves it. 



Reverse the procedure for assembling 
and installation. 



NOTE: 

After completing the reassembly operations, 
fill brake circuit with prescribed fluid. Bleed 
the air from the circuit. See the section "AIR 
BLEEDING* in chapter 3°. 



WARNING 



Replace the copper seal gaskets of brake 
hose fastening screw every time the screw 
is removed. 



7-19 



7-20 



FRONT AND REAR BRAKE 



FRONT MASTER CYLINDER DISASSEMBLY 





FRONT AND REAR BRAKE 



JOB INSTRUCTION CHART 




10 Nm (1.0 mkg) 



10Nm(1,0 mkg) 




3.5 Nm (0.35 mkg) 



15 Nm (1.5 mkg) 



Order 


Job name/Part name 


Q.ty 


Remarks 




Removal and disassembly 
of front master cylinder 




Remove the parts in the order. 
NOTE: 










Before removing the master cylinder, drain 
off the fluid from the braking circuit. 




A WARNING 






Support the motorcycle securely to 
prevent it falling oven 


1 


Nut 






2 


Bolt 






3 


Brake lever 






4 


Screw 


2 




5 
6 
7 


Stop switch 

Rubber cover (detach) 

Screw 






8 


Brake hose 






9 
10 


Joint (whit gasket) 
Screw 






11 


Screw 






12 


Screw 


2 




13 


Cover 






14 
15 


Diaphragm 
Fluid tank 






16 


Screw 


2 




17 


Bracket 






18 


Master cylinder unit 














Reverse the procedure for assembling 

and installation. 




A WARNING 






Replace the copper seal gaskets of brake 
hose fastening screw every time the screw 
is removed. 


NDTF- 








After completing the reassembly operations, 
fill brake circuit with prescribed fluid. Bleed 
the air from the circuit. See the section "AIR 










BLEEDING" in chapter 3°. 


I 



7-21 



7-22 



FRONT AND REAR BRAKE 





REAR MASTER CYLINDER DISASSEMBLY 



4 Nm (0-4 mkg) 





15 Nm (1.5 mkg) 



13 Nm (1.3 mkg) 




15 Nm (1.5 mkg) 





FRONT AND REAR BRAKE 




JOB INSTRUCTION CHART 



Order 



Job name/Part name 



Removal and disassembling 
of rear master cylinder 



1 


Brake switch 


2 


Brake hose 


3 


Joint (with gasket) 


4 


Screw 


5 


Master cylinder unit 


6 


Tank cover 


7 


Tank diaphragm 


8 


Screw 


9 


Fluid tank 



Q.ty 



Remarks 



Remove the parts in the order. 



NOTE: _ 

Before removing the master cylinder, drain 
off the fluid from the braking circuit. 



WARNING 



Support the motorcycle securely to 
prevent It falling over. 



NOTE: , 

Before removing the brake switch, disconnect 
the switch connector. 



Reverse the procedure for assembling 
and installation. 



WARNING 



Replace the copper seal gaskets of brake 
hose fastening screw every time the 
screw is removed. 



NOTE: 

Aftercompleting the reassembly operations, 
fill brake circuit with prescribed fluid. Bleed 
the air from the circuit. See the section "AIR 
BLEEDING" in chapter 3°. 



7-23 



7-24 



FRONT AND REAR BRAKE 






INSPECTION AND REPAIR 

Recommended programme for the replacement of 
brake system components: 



Pads 


When necessary 


Sealing elements, 
rear caliper dust 
cover 


Every 2 years 


Front and rear master 
cylinder unit, front caliper 


In the event of brake 
fluid leakage 


Brake hoses 


Every 4 years 


Brake fluid 


Replace only after 
disassembling brake 



WARNING 



Internal parts must be washed only with clean 
brake fluid. Do not use solvents to prevent 
sealing elements from becoming misshapen or 
swollen. 



1. 



Replace caliper 



(A} 
[BI 

2. 



Inspect: 

• Caliper pistons (1) 

Rust/Wear/Damage - 
assembly, 

• Caliper cylinder (2) 
Scratching/Wear -> Replace caliper as- 
sembly. 

Front 
Rear 

Inspect: 

• Caliper body (3) 
Cracks/Damage -» Replace. 

• Guide pin (4) 
Rust/Damage -> Repface, 

• Lock spring (5) 
Rust/Damage ~» Replace. 

• Dust seals (6) 
Cracks/Wear/Damage -* Repface. 

• Oil delivery passages (caliper body) 
Clean with compressed air. 



WARNING 



Replace the piston sealing element and dust 
seals every time the caliper is disassembled. 



FRONT AND REAR BRAKE 





B 





3. Inspect: 

• Master cylinder (1) 
Wear/Scratches ** Replace master cylin- 
der unit. 

• Master cylinder body (2) 
Cracks/Damage -» Replace. 

• Oi! feed passage (main cylinder) 
Clean with a jet of compressed air. 

[A] Front 

[B] Rear 



Inspect: 

• Master cylinder piston unit (3) 

Scratches/Wear/Damage ^ Replace mas- 
ter cylinder unit. 
Inspect: 

• Tank diaphragm (4) 
Wear/Damage -* Replace. 

• Tank (5) 
Cracks/Damage -> Replace. 

Inspect: 

• Brake hoses (6) 

• Tank hose (7) 
Cracks/Wear/Damage -» Replace. 



7-25 



7-26 



FRONT AND REAR BRAKE 





FRONT AND REAR BRAKE 






1 

f fa> 


1 P f 


_~ ' 1 




7. Measure: 

• Brake pad thickness 

Out of specification -» Replace. 




Pad wear limit (a): 
Front: 0.8 mm 
Rear: 0.8 mm 



NOTE: 



Whenever you have to replace Ihe pads, replace 
the spring too. 

Both pads have to be replaced even if only one 
is worn over the envisaged limit. 



8. Inspect: 

• Brake disk {front and rear 
Wear/Damage -» Replace 



9. Measure: 

• Brake disk wobbling 

If over envisaged limits -* Verify wheel 
centring. 

If the wheel centring is correct, replace the 
brake disk. 




Maximum wobbling: 
0,15 mm 



Brake disk thickness 

If out of specified limits -» Replace. 




Minimum thickness (a): 
Front: 3,5 mm 
Rear: 4 mm 



WARNING 



All internal parts must be cleaned using only 
new brake fluid. 

Before reassembling the components, lubri- 
cate with brake fluid. 



•Xj 



Brake fluid: 
DOT #4 



Always use new copper washers. 

Always use new piston gaskets and dust 

covers. 



NOTE: 

Apply lithium soap-base grease to Ihe brake lever 

pin. 

" ■■""■ " " ■ -.£-„....-,— 

CAUTtOM: 

The brake fluid may corrode painted surfaces 
and plastic parts. If it spills, clean immediately. 



WARNING 



The quality of the brake fluid used must 
conform to the prescribed standards, other- 
wise the rubber gaskets risk deteriorating, 
thus causing fluid leakage and poor brake 
functioning. 

Always use the same make of fluid. The 
mixing of different fluids may cause a 
chemical reaction harmful to the functioning 
of the brake. 

When adding fluid, be careful not to allow 
water to enter the tank. Water lowers the 
boiling point considerably provoking the so- 
called "vapour plug" phenomenon. 



(1) Dial gauge 



NOTE: „ 

Tighten the brake disk screws in several succes- 
sive stages in cross-over order. 




Screws (brake disk): 
Front: 23 Nm (2.3 mkg) 
Rear: 23 Nm(2.3 mkg) 

LOCTITE®242 

MEDIUM THREAD LOCKING 

LIQUID 



7-27 



7-28 



FRONT FORK 





FRONT FORK 

(1 ) Cap bolt assembly (R) 

(2) Cap bolt assembly (L) 

(3) Spring 

(4) Cylinder unit 

(5) Under spring sheet 

(6) Metal slide 



(7) Inner tube 

(8) Axie bracket 

(9) Binding head screw 

(10) Plunger 

(11) Damper rod 

(12) Outer tube 



(13) Metal slide 

(14) Oil seal washer 

(15) Oil seal 

(16) Oil seal clip 

(17) Dust seal 

(18) Wheel axle fastening screw 



20-22 Nm (2.0-2.2 m kg) 



1- 




^2 



(<-' 



•? 






"-: i 



23 Nm (2.3 mkg) 







if 



ff^rO-) 



23 Nm (2.3 mkg) 



•m 



is 



^t 



&-■ i 



20-22 Nm 
(2.0-2.2 mkg) 



CJ| 



4 _ 



L\ 






i 5- 





20+22 Nm 
(2.0-2.2 mkg) 



— 12 



11 





-10 




-10 






31 







W' 



-4 




^v 



15Nm(1.5mkg)| c^ 




FRONT FORK 




FORK OIL CAPACITY (IN EACH TUBE): 
300 cc 



RECOMMENDED OIL: BEL RAY MC 10 SAE5 



FORK OIL LEVEL: 
STANDARD: 130 mm 

From top of outer tube with inner tube and damper] 
rod fully compressed without spring. 



FORK SPRING FREE LENGTH: 
402 mm 



INNER TUBE BENDING LIMIT: 
0.2 mm 



7-29 



7-30 



FRONT FORK 





FRONT FORK 




REMOVAL 




JOB INSTRUCTION CHART 



Order 


Job name/Part name 


Q.ty 


Remarks 


1 

2 
3 

4 
5 
6 
7 

8 


Removal of front fork 

Screw (fastening brake caliper) 
Screw (fastening front fender) 
Fender 

Handle bar screw (loosen) 
Screw (handle crown) 
Screw (under bracket) 
Right fork 
Left fork 


2 

6 
1 
4 
2 
4 
1 
1 


Remove the parts in the order. 


I A WARNING ^^^^I^^^^HI 


Support the motorcycle securely to pre- 
vent it falling over. 


NOTP* 


Before removing the forks, remove side pan- 
els (R and L) of cowling (see "COWLING" in 
chapter 3) and front wheel (see "REMOVAL 

- FRONT WHEEL in this chapter). 


NHTP- 


Loosen the cap bolts before disassembling 
the front fork from the motorcycle. 

CAUTION: 


Secure the brake caliper to frame to avoid 
damaging the brake hose. 

MHTF- 


Secure odometer cable to frame to avoid 
damaging it. 

Reverse the removal procedure for In- 
stallation. 

MHTF* 


Tighten the cap botts after assembling the 
front fork to the motorcycle, 



CAUTION: 



The operations described in the following para- 
graphs In this chapter refer to the disassembly 
of the left arm. To disassembly the right arm 
proceed as for the left, being especially careful 
not to confuse the components of the two arms 
at the reassembly stage, since they are not 
interchangeable. 



7-31 



7-32 



FRONT FORK 




OIL CHANGE 

The Quality of the oil contained in the suspensions 
is of fundamental importance for obtaining maxi- 
mum performance and functioning. 
For this reason it needs to be changed after the first 
1,500 km to eliminate any residues due to the 
adaptation of the inner components and succes- 
sively every 5,000+6,000 km. 



•tt 



Recommended oil: 
BELRAYMC10SAE5 



1. Clean: 

• Suspension forks 

Generally clean the suspension. 





FRONT FORK 




4. Withdraw: 

• Cap bolt {1 ) sufficiently in order to access 
the lock nut (2) 

5. Lower: 

• Spring (3) 

NOTE: 

Lower the spring (3) using force keeping the spacer 
(4) against the spring. 

6. Release: 

• Cap bolt (1 ) and lock nut (2) 

Use a 26 mm open-ended spanner on cap 
bolt and a 1 4 mm open-ended spanner on 
lock nut. 





2. Block: 

• Suspension fork (1 ) in a vice (in the fixing 

zone of the fower bracket). 

CAUTION: 

Place a cloth between the teeth of the vice to 
protect the surface of the outer tube. Tighten 
the vice moderately in order not to ovalfze the 
outer tube. 

3. Remove: 

♦ Cap bolt (2) {loosen the cap bolt before 
disassembling the fork from the cycle) 
Use a 26 mm open-ended spanner. 



NOTE: 

To facilitate coming out of cap bolt push up the axle 
bracket as shown. 





7. Unscrew: 

• Cap bolt (1) (completely) 

8. Withdraw: 

• Spacer (2) 

NOTE: 

Place all the components in a dean area. 



9. Withdraw: 

• Spring (1) from the outer tube (2) 

NOTE: 



The spring, being immersed in oil could cause oil to 
drip onto the work surface when withdrawn. It is 
advisable therefore to withdraw it slowly and to dry 
it with a cloth. 



7-33 



7-34 






FRONT FORK 





10. Remove: 

• Outer tube trom the vice 

Keep the cap bolt end upwards. 

1i; Pour: 

• Oil (into a tray) 

NOTE: 

While pouring the oil at the same time move the rod 
(1) backwards and forwards. 



12. Pour in: 

• Part of the new oil (with the suspension in 
a vertical position) 



Aft 



Recommended oil: 

BEL RAYMC10SAE5 



13. Pump: 

• The rod (1) and axle bracket (2) attached 
to inner tube {alternatively until braking in 
the return run stroke feets homogenous). 

NOTE: 

During this operation it is advised to keep a finger 
over the hole on the end of the rod (1) in order to 
avoid possible oil splashes. 





FRONT FORK 




14. Compress: 

• Outer tube (1) and rod (2) (completely to 
the end of the stroke) 

15. Complete: 

• Topping up of oil 



Topping up procedure: 

• Keep the fork in a perfectly upright position. 

• Bring the level to 130 mm from the upper edge 
measured with a graduated dipstick or ruler. 

• Only when the fork is completely dismounted in 
order to replace the seals/bushes or the inner 
tube can one use 300 cc of oil without measuring 
the level with a ruler. In all the other operations 
check the quantity of oil by measuring the level 
with a ruler, * 




Oil level: 
1 30 mm from the upper edge (with 
inner tube and damper rod fully 
compressed without spring) 



•X} 



Recommended oil: 
BEL RAY MC 10 SAE5 



ft * * ft * 



* a 



* ft * 



+ # * * « 



16. Insert: 

• Spring (1 ) into the outer tube (2) 



NOTE: — - — 

Usually there is no particular sense in which the 
spring is mounted and so it may be inserted from 
either end. 



7-35 



7-36 



FRONT FORK 





1 7. Screw: 

• Lock nut (1 ) (by hand until it becomes light) 

18. Insert: 

• Spacer (2) 

19. install: 

• Cap bolt (3) (tighten until it becomes tight) 




FRONT FORK 




CLEANING THE DUST SEAL 

If dusty or muddy roads are frequently driven on it 
is advisable to clean the dust seal regularly in order 
to maintain the suspension at maximum efficiency, 
In fact, if dust infiltrates to the inside of the dust seal 
it can compromise the smoothness, and therefore 
the sensitivity of the suspension, and also cause 
the premature wear of the underlying oil seal- 
Just a few simple operations then, guided by the 
following indications are necessary to maintain the 
optimum functioning of the suspension with time, 





1 




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Cap bolt and spacer installation procedure: 

• Check that there is a space of about 1*2 mm 
between the cap bolt (1) and the lock nut (2) so 
ensuring that the cap bolt is completely tightened 
onto rod (3). 



CAUTION: 



This check ensures a maximum traction seal. 



Lower the spring using force keeping the spacer 
(4) tight against the spring (5), then insert a 14 
mm open-ended spanner on lock nut (2) and a 26 
mm open-ended spanner on cap bolt (1 ); tighten 
the two components to the specified torque. 




Cap bolt (1) and lock nut {2): 
20-^22 Nm{2.0-2.2mkg) 



20. Screw: 

• Cap bolt (1) onto the outer tube (2) (by 
hand for the first few turns, then using a 26 
mm open-ended spanner) 

21. Tighten: 

• Cap bolt (1) (to specified torque) 




\ 



Cap bolt: 

2G-r22Nm(2.0-2.2mkg) 



NOTE: _ , „ 

Tighten the cap bolts after assembling the front fork 
to the motorcycle. 




1} 

4 

f 

w 

h 
W 

1 

i 

i 

\ 
j 


3 

i 
j 






2 
/ 




1. Block: 

• Suspension fork (1 ) in a vice (in horizontal 
position in the fixing zone of brake caliper 
onto axle bracket) 

NOTE: 

Place a cloth between the teeth of the vice to protect 
the surface of the axfe bracket. 



2. Dismount: 

• Dust sea! (2) from outer tube (3) 

3. Withdraw: 

• Dust seal (completely) 



********** 



* w * * m ft 



************ 



Dust seal dismounting sequence: 

• With a screwdriver, prise the dust seal (2) from 
the outer tube (3). 

• Then withdraw the dust seal using force. 



7-37 



7-38 



FRONT FORK 








4. Clean: 
• Dust seal 



* * * 



* * 



* * 



******** 



* * * * * 



Dust seal cleaning procedure: 

• Using a low pressure jet of compressed air cfean 
the inside of the dust seal and the outer tube. 

• Insert the edge of a cloth under the lip and, 
keeping the cloth steady, carefully clean the lip 
by rotating the dust seal. 

• Using a small screwdriver take a small amount of 
silicon grease and insert it under the lip paying 
attention not to scratch it. 

• Lubricate the dust seal by rotating it in such a 
manner that the grease is distributed in the inner 
part of the lip. 



5. Remount: 
• Dust seal 



Dust seal remounting sequence: 

• Remount the dust seal inserting it with force into 
the outer tube, 

• Check that the cup edge of the dust seal adheres 
perfectly to the cup. 



FRONT FORK 




REPLACING SEALS AND BUSHES 

To ensure maximum efficiency of the suspension 
and therefore a greater duration and safety, every 
10,000 km it is necessary to replace all the seals 
and slide bushes. 



CAUTION; 




The operations sequence shown in the draw- 
ings in the following paragraph refer to the 

disassembly and reassembly of the left arm. It 
is fundamental to remember that the parts dis- 
assembled from this arm should be reassem- 
bled on it and not on the right arm, since - as it 
is possible to note when disassembling the 
arms, the adjustment rod of the left arm cap bolt 
is much shorter than the one on the right arm. 
Remember also that the cartridges are differ- 
ent. Be careful not to confuse them at the 
reassembly stage. 



1. Clean: 

• Suspension forks 

Generally clean the suspension 

2. Block: 

• Suspension fork (1 ) in a vice (in the fixing 
zone of the lower bracket) 

CAUTION: 

Place a cloth between the teeth of the vice to 
protect the surface of the outer tube. Tighten 
the vice moderately in order not to ovallze the 
outer tube. 




3. Remove: 

• Cap bolt (2) (loosen the cap bolt before 
disassembling the fork from the cycle) 
Use a 26 mm open-ended spanner. 



NOTE: - 

To facilitate coming out of cap bolt push up the axle 
bracket as shown. 



7-39 



7-40 



FRONT FORK 





FRONT FORK 






4. Withdraw; 

• Cap boft (1 ) sufficiently in order to access 
the lock nut {2} 

5. Lower: 

• Spring (3) 

NOTE: ^___ 

Lower the spring (3) using force keeping the spacer 
(4) against the spring, 

6. Release: 

• Cap bolt {1 ) and lock nut (2) 

Use a 26 mm open-ended spanner on cap 
bolt and a 1 4 mm open-ended spanner on 
lock nut. 

7. Unscrew: 

• Cap bolt (1) (completely) 

8. Withdraw: 

• Spacer (2) 

NOTE: _^____ 

Place all the components in a clean area. 



9. Withdraw: 

• Spring (1) from the outer tube (2) 

NOTE: 



The spring, being immersed in oil could cause oil to 
drip onto the work surface when withdrawn. It is 

advisable therefore to withdraw it slowly and to dry 
it with a cloth. 





10. Remove: 

• Outer tube from the vice 

Keep the cap bolt end upwards. 

11. Pour: 

• Oil {into a tray) 

NOTE: 

While pouring the oil at the same time move the rod 
(1) backwards and forwards. 




12. Block: 

• Suspension fork (1 ) in a vice {m horizontal 

position in the fixing zone of brake caliper 
onto axle bracket) 

NOTE: 

PJace a cloth between the teeth of the vice to protect 
the surface of the axle bracket. 

13. Uscrew: 

• Lock nut (2) 

Use a 14 mm open-ended spanner 

14. Withdraw: 

• Lock nut (2) 

• Spacer (3) 

• Pfastic spring guide (4) 

• Spacer (5) 



7-41 



7-42 




FRONT FORK 









^^^ 










-, 
















2 




s^ £-4 ■: J>- y/ 





15. Loosen: 

• Cartridge (1) 

Use special tool (2) provided in the fork 
service kit assy 



p 



Fork service kit assy: 

P/N 4SU-F8120*W0 



- *%s 



16. Unscrew: 

♦ Cartridge (1) (completely) 

17. Withdraw: 

♦ Cartridge (1) 

NOTE; 



During unscrewing ensure that the end of the 
spanner (2) is correctly engaged on the cartridge 
(1). 



18. Empty: 

• Cartridge (1) 



Draining oil procedure from the cartridge: 

• Empty the cartridge completely by pumping the 
rod (3) backwards and forwards. 

NOTE: _____^___ 

During this operation it is recommended to keep a 
finger over the hole on the end of rod (3) to avoid oil 
splashes. 



FRONT FORK 




19. Cfean: 

♦ Outer tube (inside) 

• Cartridge (outside) 



Cleaning procedure: 

• Clean the inside of the outer tube and the outside 
of the cartridge with cfean petrol taking care not 
to let petrol enter the inside of the cartridge 
through the two lower holes as it would seriously 
jeopardize its functioning. 




WARNING 



Never tamper with the cartridge! Tampering 
with the cartridge can jeopardize the safety of 

the front fork. 

± 

20. Prise: 

• Dust seal (2) from the outer tube (3) 

21. Withdraw: 

• Dust seal (completely) 



ll 


3 


} \ 


2 

k 



Dust seal dismounting sequence: 

• With a screwdriver prise the dust (2) from the 
outer tube (3). 

• Withdraw the dust seal using force. 




7-43 



7-44 



FRONT FORK 



CHAS^3fe 




\ 







, */Sfr//s 



-. QZBtCM 

* nTTTTT. 



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22. Withdraw: 

• Oil seal clip (1 ) (from its seat) 

CAUTION: 



Use a screwdriver to withdraw the clip, taking 
care not to scratch the outer tube. 



23. Withdraw: 

• Outer tube (1 ) from inner tube (2) 
(with a few sharp blows) 

NOTE: 



The oil seal (3), the washer (4), the DU bush (5) for 
the outer tube and the DU bush (6) for the inner tube 
are present on the inner tube and must be removed 
and substituted. 



24. Withdraw: 

• Ail parts from inner tube (one at a time) 

25. Replace (one at a time): 

• Dust seal (7) 

• Oil seal (3) 

• Washer (4) 

• DU bush (5) for the outer tube 

• DU bush (6) for the inner tube 

NOTE: 

Check that the DU bush (6) for the inner tube is 

fitted properly inside its housing at the end of the 
inner tube (2). 



CAUTION: 



Unlike the two DU bushes (5 and 6) and the 
washer (4), the oil seal (3) and dust seal {7) have 
to be fitted to the inner tube in a specific direc- 
tion. This must be respected at all times avoid 
compromising the functioning of the front fork. 




FRONT FORK 






26. Assemble: 

• DU bush (5) into the outer tube 



Sequence of DU bush assembly: 

• Take the outertube DU bush (5) by the outertube 
housing side and assemble the special tool (8), 
supplied in the kit, to the inner tube (2). 



^ 



Fork service kit assy: 
P/N4SU-F8120-W0 



Assemble the tool with bush fitting side (9) facing 
the outer tube DU bush (5), remembering to 
leave the dust seal (7), oil seal (3) and washer (4) 
on the other side of the vice on which the axle 
bracket is positioned. 

Lock tool (8) in a vice, holding the joint sides (10) 
facing upwards and downwards, and making the 
tool Jut out sideways on the outertube (t) and DU 
bush (5) by at least 40 mm from the vice. 
After locking the vice, hold the outer tube firmly, 
and then vigorously push it against the tool until 
the outer tube DU bush (5) enters tightly into its 
housing. 

Remove the suspension fork from the vice and 
disassemble the tool. 




7-45 



7-46 





FRONT FORK 




27. install: 

* Oil seal (3) onto the outer tube 



Oif seal mounting sequence: 

• Take the washer (4) and oil seal (3) by the outer 
tube housing side and assemble the special tool 
(8) to the inner tube (2) with oil seal fitting side 
(1 1) facing the oil seal (3), remembering to leave 
the dust seal (7) on the other side of the vice on 
which the axle bracket (12) is positioned. 

• Lock tool (8) in a vice, holding the joint sides (10) 
facing upwards and downwards, and making the 
tool jut out sideways on the outer tube (1 ) and oil 
seal (3) by at least 40 mm from the vice. 

• After having tightened the vice, grip the outer 
tube and with a few energetic blows, hit it against 
the tool; after each blow rotate the outer tube 
slightly in order to mount the oil seal correctly and 
until it is completely in its seat 

• Remove the suspension fork from the vice and 
disassemble the tool- 



* * * 



************** 



* * * 



* * * 








FRONT FORK 




28. Clamp: 

• Suspension fork 

NOTE: 



Clamp the suspension horizontally in the vice fas- 
tening it by brake caliper attachment on the axle 
bracket. 



29. install: 

• Oil seal clip (1 ) 

CAUTION: 



Check that the stop ring is correctly seated 
inside the outer tube (2). 



30. Install (using force): 

• Dust seal (1) (new) onto outer tube (2) 



NOTE: ^___ — 

Check that the cup edge of the dust seal adheres 
perfectly to the outer tube. 



7*47 



7-48 



FRONT FORK 






31. Install: 

• Cartridge (1 ) into outer tube (2) 

Mounting procedure: 

• After having checked that the cartridge and the 

inside of the outer tube are clean, pour a few 
drops of medium thread locking compound 
LOCTITE* , 242 on the first 2*3 complete turns of 
the thread of the cartridge. 

NOTE: - 

Remove any traces of oil that there may be on the 
cartridge thread and on the caliper bracket as it couid 
jeopardize the locking properties of the thread locking 
liquid. 

• Mount the cartridge using the socket spanner (3) 
provided in the fork service kit assy. 




Fork service kit assy: 
P/N 4SU-F8120-WO 



Tighten the cartridge to the specified torque. 




Cartridge: 

25 Nm {2.5 mkg) LOCTITE* 242 



CAUTION: 



During tightening ensure that the end of the 
spanner (4) is correctly engaged on the car- 
tridge (1). 



FRONT FORK 





32. Insert: 

• Spring (1) in the outer tube (2) 

NOTE; 



Usually there is no particular sense in which the 
spring is mounted and so it may be inserted from 

either end, 

33. Install (one at a time): 

• Spacer (3) 

• Plastic spring guide (4) onto inner tube (5) 

• Spacer (6) with holes corresponding wilh 
those on the rod 

34. Screw; 

• Lock nut (7) (down to bottom of thread) 




35. Remove: 

• Suspension fork (from 

the vice) 

36. Fill: 

• New oil (in the suspen- 
sion fork) 

37. Check: 

• Oil level 

See the "OIL CHANGE" 
paragraph in this chap- 
ter. 




NOTE: . . 

Remember that these operations and illustrations 
refer to the left arm. The only difference between 
the two amis is that the setting rod (1 ) of the cap bolt 
(2) on right arm is shorter than the one on the left 
arm cap. 

38. Screw: 

• Lock nut (3) (by hand until it becomes tight) 

39. Insert: 

• Spacer (4) 

40. Install: 

• Cap bolt (2) (until it becomes tight) 



7-49 



7-50 



FRONT FORK 







Cap bolt and spacer installation procedure: 

• Check that there is a space of about 1+2 mm 

between the cap bolt (1) and the fock nut (2) so 
ensuring that the cap bolt is completely tightened 
on to rod (3). 



CAUTION: 



This check ensures a maximum traction seal. 



Lower the spring using force keeping the spacer 
(4) tight against the spring (5), then insert a 14 
mm open-ended spanner on lock nut (2) and a 26 
mm open-ended spanner on cap bolt (1 ); tighten 
the two components with the specified torque, 




Cap bolt (1) and lock nut (2): 
20 + 22Nm(2.0-2.2mkg) 



41. Screw: 

♦ Cap bolt (1) onto the outer tube (2) (by 
hand for the first few turns, then using a 26 
mm open-ended spanner) 

42. Tighten: 

• Cap bolt (1) (to specified torque) 




Cap bolt: 
20 * 22 Nm (2.0 * 2.2 mkg) 



NOTE: — — 

Tighten the cap bolts after assembling the front fork 
to the motorcycle. 






FRONT FORK 




ADJUSTMENT 

Fork damper adjustable both in extension (right 
stem adjustment) and compression (left stem ad- 
justment). 



CAUTION: 



Do not force the adjusting screw beyond the 
minimum and maximum limits. 

ADJUSTING THE REBOUND DAMPING EFFECT 

1. Adjusting screw (rebound damping effect): 

A. Increase damping effect 

B. Decrease damping effect 



ADJUSTMENT RANGE 


Maximum 


Minimum 


Screw fully 
turned 
clockwise (A) 


Screw turned 
counterclockwise 
by 24 steps (B) 


Standard adjustment: 13 steps from maximum 



ADJUSTING THE COMPRESSION DAMPING 
EFFECT 

2. Adjusting screw (compression damping ef- 
fect): 

A. Increase damping effect 

B. Decrease damping effect 



ADJUSTMENT RANGE 



Maximum 

Screw fully turned in 

Standard setting 

13 step from maximum 

Minimum 

24 steps counterclockwise (B) from 

maximum 



7-51 



7-52 



STEERING 





STEERING - REMOVAL 




STEERING 




JOB INSTRUCTION CHART 



Order 



1 
2 
3 

4 

5 



Job name/Part name 



Removal of steering 



Screw 

Handle bar (l) 

Screw 

Handle bar (R) 

Main switch connector 



6 


Crown nut 


7 


Handle crown 


8 


Special washer 


9 


Ring nut (use special wrench) 


10 


Plate washer 


11 


Ring nut (use special wrench) 


12 


Cover (upper bearing) 


13 


Upper bearing 


14 


Steering axle (with lower bracket) 


15 


Lower bearing 



Q.ty 



1 
1 

1 
1 



1 
1 
1 
1 
1 
1 



Remarks 



Remove the parts in the order. 



WARNING 



Support the motorcycle securely to 
prevent it from falling over. 

NOTE: 

Before removing the steering parts, remove 
the cowling (see "COWLING" in chapter 3), 
the front wheel and the suspension forks 
(see"REMOVAL-FRONT WHEEL" and H RE- 
MOVAL-FRONT FORK" in this Chapter). 



NOTE: 

If the handle crown does not need to be 

replaced, do not disassemble the main 
switch, which is fixed with two special screws. 



/*• 



Ring nut wrench: 
P/N 90890-01385 



NOTE: . — 

Disassemble the outer bearing rings only 
when they are to be replaced. 

Reverse the removal procedure for 
reassembty. 

NOTE: __ ( 

To reassemble, see also the instructions in 
the 'INSTALLATION* paragraph. 



7-53 



7-54 



STEERING 




(1) Crown nut 

(2) Handle crown 

(3) Special washer 



(4) Ring nut 

(5) Plate washer 

(6) Cover (upper bearing) 



(7) Upper bearing 

(8) Lower bearing 

(9) Steering axle 



110 Nm (11.0 mkg) 



Tightening sequence: 



# Tighten to 38 Nm (3.8 mkg) 

• Loosen one turn 

* Final tightening 3 Nm (0.3 mkg) 



23Nm(2.3 mkg) 



23 Nm (2.3 mkg) 





-m 







W 




*?*. 



w 





"V*^*< 



"*■£*€;?; 




STEERING 




INSPECTION 



BEARINGS 



1. Wash the bearings in clean solvent. 

2. Inspect: 

• Bearing (upper and lower) (1) 

Corrosion/Damage -> Replace races and 

bearing. 

Install the bearings in the races. Spin the 

bearing by hand. 

If the bearing rises or fails to run freely in 

the race, repface bearing and race. 



STEERING AXLE 

1. Inspect: 

• Steering axie (1) 
Bend/Damage -» Replace. 

INSTALLATION 

Perform "REMOVAL" operations in reverse order. 
Note the following points. 

UNDER BRACKET 

1. Install: 

• Bearing (1) 

• Ball race cover (2) 

NOTE: 

Apply lithium soap-base grease to the bearing and 
ball race cover lip. 



2. install: 

• Under bracket (1) 

NOTE: 



Apply lithium soap-base grease to the bearing. 



7-55 



7-56 





■jjf 



\ 



M 



J***& 



STEERING 





3. install; 

• Ring nut (lower) (1) 

Use the ring nut wrench (2) 



¥- 



Ring nut wrench: 
PfU 90890-01385 



NOTE: „ 

Apply the lithium soap-base grease to the steering 

axle thread. 




Ring nut tightening sequence; 

• Tighten the ring nut using the ring nut wrench. 



Ring nut (lower) 
{initial tightening): 
38Nm(3.8mkg) 



• Loosen the ring nut {1} completely and 
retighten it to specification. 



WARNING 



Do not tighten excessively. 




Ring nut (lower) 
(final tightening): 
3Nm(0.3kgm) 



4. Check the steering axle by turning it lock to 
lock. If there is any binding, remove the steer- 
ing axle assembly and inspect the steering 
bearings. 



STEERING 





5. Install: 

• Plate washer 

• Ring nut (upper) (1) 

• Lock washer (2) 



Installation sequence 

• Install the plate washer on the lower ring nut. 

• Install the ring nut (upper) (1). 

• Finger tighten the ring nut (upper), then align 
the slots of both ring nuts. If not aligned, hold 
the lower ring nut and tighten the upper ring nut 
until they are aligned. 

• Install the lock washer (2). 



NOTE: ., 

Make sure the lock washer tab is in the slots. 




NOTE: 

When reassembling the arms of the front fork, pay 
attention to the jut of the outer tubes in relation to 
handle crown. 




Front fork top end (a) 
(Standard): 

0±0.5mm 



7-57 



7-58 



REAR SHOCK ABSORBER 





REAR SHOCK ABSORBER - REMOVAL 




JOB INSTRUCTION CHART 



Order 


Job name/Pad name 


Q.ty 


Remarks 


1 
2 

3 
4 
5 


Removal of rear shock absorber 

Nut 

Screw (lower) 

Nut 

Screw (upper) 

Shock absorber 


i 

I 
1 

1 ! 

i 
•i 

1 
1 
1 


Remove the parts in the order. 


A WARNING 




Support the m 
prevent It from f; 


otorcycle securely to 
ailing over. 


A WARNING 




Support the real 
the lower screw. 


r wheel when removing 


Reverse the removal procedure for 
installation. 



REAR SHOCK ABSORBER 




(1) Shock absorber 

(2) Spring 



(3) Spring adjuster nut 

(4) Lock ring nut 




40 Nm (4.0 mkg) 



42Nm{4.2mkg) 





A WARNING 



This shock absorber contains high-pressure 
nitrogen gas. Read the following information 
carefully before handling it. The manufacturer 
cannot be held responsible for any damage or 
injury that may result from improper handling. 

♦ Never tamper with or attempt to open the 
cylinder or the tank. 

• Never expose the shock absorber to a naked 



fiame or other source of heat. This might 
cause the pressurised gas to explode. 
Do not deform or damage the cylinder In any 
way. Damage to the cylinder would impair the 
damping effect. 

Be careful not to scratch the surface of the 
rod: this would cause the oil to leak. 
Before disposing of the shock absorber, read 
the section "NOTES ON DISPOSAL". 



7-59 



7-60 



REAR SHOCK ABSORBER 








NOTE ON DISPOSAL 

Before neutralising the rear shock absorber: 
The gas pressure must be discharged before 
disposing of the shock absorber. To do this, bore a 
hole of 2-3 mm through the cylinder wall about 
15-20 mm from the bottom of the gas chamber. 



A WARNING 



Wear protective goggles to avoid eye injuries 
from escaping gas and/or metal chips. 



INSPECTION 

1. Examine; 

• Shock absorber 
Oil leak/Damaged 



Replace. 



ADJUSTMENT 



SPRING PRELOAD ADJUSTMENT 



NOTE; 



When adjusting the spring preload, use the special 
wrench provided. One complete turn of the adjuster 
will change the preload by 1 mm. 

1 . Adjuster 

2. Lock nut 




Spring adjuster lock nut: 
42 Nm (4.2 mkg) 




Spring length with preload; 
Standard length: 166 mm 
Minimum length; 161 mm 
Maximum length: 170 mm 



REBOUND DAMPING EFFECT ADJUSTMENT 

To increase the rebound damping effect, turn 
clockwise (A) the adjuster (3) located on the base 

of the shock absorber; to decrease it, turn the 
adjuster counterclockwise (B). 




Adjustment range: 

Maximum effect: adjuster completely 

screwed in. 

Standard setting: adjuster turned by 

10 steps from maximum. 




SWING ARM 




SWING ARM 

(1) Chain case 

(2) Swing arm 

(3} Guard seal chain 



(4) Arm 

(5) Arm reiay 



9 Nm (0.9 mkg) 



«L5n 




40 Nm (4.0 mkg} 



ONm (11.0 mkg) 



,\ i 5 Nm (0.5 mkg) 



Mi^l 



7-61 



7-62 



SWING ARM 





SWING ARM 




REMOVAL 




JOB INSTRUCTION CHART 






Order 


Job name/Part name 


; g 

Q.ty 


Remarks 


1 

2 

3 
4 

5 

6 
7 
8 
9 
10 


Removal of swing arm 

Screw 

Sproket cover 

Chain joint 

Chain 

Rear brake caliper 

Nut (arm reiay) 

Screw 

Nut (swing arm axle) 

Swing arm axle 

Swing arm 


2 

1 
1 
1 

1 


Remove the parts in the order. 


■ A WARNING ■■^^^■^^^■j 


Support the motorcycle securely to 
prevent it from falling over. 

NOTFr 


Before removing the swing arm, remove the 
rearwheel (see "REMOVAL-REAR WHEEL" 
and "REAR SHOCK ABSORBER" in this 
chapter. 

CAUTION: 


After detaching the rear brake hose 
secure the rear brake caliper to chassis 
to avoid damaging the brake hose. 

Reverse the removal procedure for 
installation. 



7-63 



7-64 



SWING ARM 





SWING ARM 




INSPECTION 

1. Check: 

• Swing arm free play 

NOTE: 



4. 



Check swing arm free play after removing the rear 
shock absorber. 



inspect: 

• Oil seals 
Wear/Damaged • 

• Washers 

• Thrust cover 
Wear/Damaged - 

• Bearings 
Pitting/Damaged 



Replace. 



Replace. 



Replace. 



5. 



Inspection procedure: 

• Check the tightening torque of the nut which 
fastens the swing arm axle. 



Inspect: 

• Chain guide 

• Chain protection 
Wear/Damage -> Repface 




Nut {swing arm axle): 
110 Nm (11.0 mkg) 



Check the lateral free play of the swing arm 
moving it laterally. 

If the free play seems excessive, verify the 
collar, bearings, washers and thrust covers. 




Lateral free play 

(at end of swing arm): 

Limit: 1.0 mm 



Check the vertical movement of the swing 
arm, moving it up and down. 
If the movement seems rigid, unsmooth or 
jerky, inspect the internal collar, the bearings, 
the washers and the thrust covers. 



2. Inspect: 

• Swing arm 

Deformation/Cracks/Damage ~> Replace. 

3. Inspect: 

• Articulation 

• Rods 
Deformation/Cracks/Damage 



Replace. 



7-65 



7-66 



DRIVE CHAIN, SPROCKET AND CROWN WHEEL 
DRIVE CHAIN, SPROCKET AND CROWN WHEEL - REMOVAL 





110 Nm {11,0 



10Nm(t.0mkg) 



80 Nm (8.0 mkg} 



{23 Nm {2.3 mkg) 



13 




DRIVE CHAIN, SPROCKET AND CROWN WHEEL 




JOB INSTRUCTION CHART 



Order 


Job name/Part name 


Q.ty 


Remarks 




Removal of drive chain, sprocket 




Remove the parts in the order. 




and crown wheel 








A WARNING 




Support the motorcycle securely to 








prevent it from falling over. 








NOTE: 








Check drive chain wear before removing it 








(see "INSPECTION" in the next page). 


1 


Screw (sprocket cover) 


2 




2 


Sprocket cover 


1 


■■ 


3 


Lock washer 




4. 




(straight the tab) 


1 




4 


Sprocket nut 


1 


MOTF* 










Loosen the sprocket nut with the rear brake 








pulled- 


5 


Chain joint 


1 




6 


Drive chain 


1 




7 


Sprocket gear 


1 




8 


Nut (wheel axle) 


1 




9 


Chain stretcher (loosen) 


2 




10 


Wheel axle 


1 




11 


Wheel 


1 




12 


Screw 


6 




13 


Crown wheel 


1 


Reverse the removal procedure for 
installation. 

MOTF- 








Tighten the sproket nut with the rear brake 








pulled- Then adjust drive chain tightness (see 








'DRIVECHAlNTiGHTNESS ADJUSTMENT* 








in chapter 3). 



7-67 



7-68 



DRIVE CHAIN, SPROCKET AND CROWN WHEEL 









INSPECTION 

1 . Measure: 

* Length of 10 links (drive chain) 

Out of specification -» Replace drive chain 




Maximum lenght of 10 links (a): 
150.0 mm 



NOTE: 



Stretch the chain by hand to measure it. 
The length of the 10 links is recorded between 
the inside of the link pins (1 ) and (11 ) as shown. 
The length of the to links is measured at various 

points. 




2. Clean: 

• Drive chain 

Immerge in kerosene and brush thoroughly 
to remove as much dirt as possible. 
Remove from kerosene and allow to dry. 



CAUTION: 



This motorcycle is fitted with a chain with small 
O-rings (1) fitted between its plates. Vapour 
cleaning, pressurised washing and certain types 
of solvents may damage these seal rings. 
To clean the transmission chain use only 
kerosene. 




3. Inspect: 

• Seal rings (1) (drive chain} 
Damaged -» Replace drive chain. 

• Rollers (2) 

• Lateral plates (3) 
Damage/Wear -* Replace drive chain 




DRIVE CHAIN, SPROCKET AND CROWN WHEEL 






4. Inspect: 
• Chain joint 

Damage/Wear/Distortion of lock spring -> 
Replace joint assembly. 



5. Lubricate: 

• Drive chain 



V^_ Lubricant for drive chain; 
\T Engine oil SAE 30W - 50 



6. Inspect 

• Drive chain 

• Rigid -» Clean and lubricate, replace if 
necessary. 



7. 


Inspect; 




• Sprocket gear 




♦ Crown wheel 




• Wear over 1/4 tooth (1 ) 




Teeth bent -» Replace. 


(2) 


Undamaged tooth profile 


(3) 


Roller 


(4) 


Sprocket 



Replace. 



7-69 



7-70 




CHAPTER 8° 
ELECTRICALS 





ELECTRICAL CIRCUIT DIAGRAM K-6 

COLOUR CODE K-6 

ELECTRICAL COMPONENTS K-7 

SWITCH CHECK K-8 

SWITCH CONNECTION K-8 

MAIN SWITCH INSPECTION K-8 

LIGHT INSPECTION {HEADLIGHTS, TAIL LIGHT AND BRAKE LIGHT, 

DIRECTION INDICATOR LIGHTS, INSTRUMENT LIGHTS, ETC) K-9 

BULB TYPES K-9 

BULB INSPECTION K-9 

IGNITION SYSTEM K-10 

CIRCUIT DIAGRAM K-10 

DIAGNOSTICS K-11 

ELECTRICAL STARTING SYSTEM K-15 

CIRCUIT DIAGRAM K-15 

STARTING CIRCUIT FUNCTIONING K-16 

DIAGNOSTICS K-16 

STARTER MOTOR L-3 

CHARGING SYSTEM L-6 

CIRCUIT DIAGRAM L-6 

DIAGNOSTICS L-7 

LIGHT SYSTEM L-9 

CIRCUIT SYSTEM L-9 

DIAGNOSTICS L-10 

SIGNALLING SYSTEM L-12 

CIRCUIT DIAGRAM L-12 

DIAGNOSTICS L-13 

SIGNALLING SYSTEM CONTROL L-14 

COOLING SYSTEM M-3 

CIRCUIT DIAGRAM M-3 

DIAGNOSTICS M-4 

ELECTRICAL SYSTEM DIAGRAM M-8 



ELECTRICAL CIRCUIT DIAGRAM 



ELECTRICALS - electrical circuit diagram 





®% QCP-fe ®W 




©^ff © © @ © @ © 



ELECTRICAL CIRCUIT DIAGRAM 




(1) CDIunit 

(2) Fan motor 

(3) Fuse (fan motor) 

(4) Thermo switch 

(5) Thermo unit 

(6) Main switch 

(7) Clutch switch 

(8) Front brake switch 

(9) Ignition coil 

(10) Sparkplug 

(11) Rear brake switch 

(12) Side stand switch 

(13) AC generator 

(14) Rectifier/Regulator 

(15) Rear stop/tail light 

(16) Right rear direction indicator light 

(17) Left rear direction indicator light 

(18) 8attery 

(19) Fuse (main) 

(20) Starting motor relay 

(21) Starting motor 

(22) 1 diode (starting circuit) 

(23) Neutral switch 



COLOUR CODE 



(24) 2 diode (ignition circuit) 

(25) Starting switch 

(26) Engine stop emergency switch 

(27) Horn switch 

(28) Direction indicator tights switch 

(29) Driving beam/dimmers lights switch 

(30) Lights switch 

(31) Low fuel warning light switch 

(32) Horn 

(33) Direction indicator lights relay 

(34) Left front direction indicator light 

(35) Right front direction indicator light 

(36) Engine temperature cooling liquid indicator 

(37) Driving beam light 

(38) *N* neutral light 

(39) Low fuel light 

(40) Control light 

(41) Front parking light 

(42) Headlight (dipped/high beam) 

(43) Direction indicator light 

(44) Rev. counter 

(45) Number plate light 



B 


Black 


B/W 


Black/White 


Br 


Brown 


B/Y 


Black/Yellow 


Ch 


Chocolate 


Br/W 


Brown/White 


og 


Dark grey 


G/W 


Green/White 


G 


Green 


G/Y 


Green/Yellow 


L 


Blue 


L7R 


Blue/Red 





Orange 


L/Y 


Blue/Yellow 


P 


Pink 


LAV 


Blue/White 


R 


Red 


R/W 


Red/White 


Sb 


Sky blue 


R/Y 


Red/Yellow 


W 


White 


Y/R 


Yellow/Red 


Gy 


Grey 


G/R 


Green/Red 


Y 


Yellow 


W/L 


White/Blue 


B/R 


Black/Red 







8-1 



8-2 



ELECTRICAL COMPONENTS 





ELECTRICAL COMPONENTS 



ELECTRICAL COMPONENTS 

(1) Harness 

(2) Diode 

(3) Fuse 7.5A (fan motor) 

(4) Main switch 

(5) Ignition coil 

(6) Spark plug cap 

(7) Rear brake switch 

(8) Fuse 20A (main) 

(9) Rectifier/Regulator 

(10) CD! ignition unit 

(11) Battery (12V-8Ah) 



IGNITION COIL: 

PRIMARY WINDING RESISTANCE: 
3.4 ~ 4.6 Q at 20°C (68°F) 

SECONDARY WINDING RESISTANCE: 
10.4- 15.6 kil at 20°C(68T) 



BATTERY; CAPACITY 12V - 8Ah 

ELECTROLYTE DENSITY 1.320 



(1) 


Starting motor relay assembly 


(2) 


Thermo switch 


(3) 


Thermo unit 


W 


Flasher relay assembly 


(5) 


Horn 


(6) 


Neutral switch 


(7) 


Side stand switch 






8-3 



8-4 



SWITCH CHECK 




SWITCH CHECK 

Check the continuity between the switch terminals 
to verify whether connections are correct- 
To check the switch, read the following points. 



SWITCH CONNECTION 

The table shown here contains the connections 
between the switch terminals (eg main switch, 
handlebar switches, brake switch, light switch etc). 

The column on the far left shows the positions of the 
main switch and the top line indicates the colours of 
the cables connected with the terminals of the 
switch itself. 



■o" indicates the terminals between which 



there is electrical continuity, ie a closed circuit on 
the respective switch positions. 

For example, in this table: 

W R and Br" and *L and L/R" are continuous when the 

switch is at ON. 

B R and L/R" are continuous when the switch is at 

PARK. 









^^ 


R 


Br 


L 


L/f 


\ 


ON 


o 


■0 


O 


-o 




OFF 






LOCK 










P 










t^ 




1 — HJ 






| IrI 1 






«■ 


1 kn 

L/R] 




R 


Br 









MAIN SWITCH INSPECTION 

Before inspecting the switch, see the connection 

table shown above and check the terminal connec- 
tions (closed circuit) by the colour combination. 

1. Detach the main switch connector from the 
harness connector. 




SWITCH CHECK 





CAUTION: 









"^\. } 


* Br 


L 


L/F 


I 


ON 0-O 


o 


-0 




OFF 






LOCK 








P ( 


■vl, I 




r\ 




^1 




~\J 




L lfl _ I 






} 1 1 

L L/RJ 




R j Br 









When detaching the connector, do not pull by 
the cables. This way the cables might discon- 
nect from the terminals inside the connector 
itself. 

2. Check to see if any cables are disconnected 

from their terminal inside the connector. Re- 
connect, if necessary. 

NOTE: 

If the connector is blocked up with mud or dust, 
clean it with a jet of compressed air. 

3. Use the connection table to check the combi- 
nation of colours for continuity (closed circuit). 
in this example, continuity Is as follows: 

"R and Br" and "L and L/R" are continuous 
when the switch is at ON. 

"R and UR* are continuous when the switch is 
at PARK. 

Note that there is no continuity (open circuit) 
for any of the combinations of a colour differ- 
ent from those mentioned. 

4. Check the switch component for continuity 
between "R and Br* and T and L7R" and 
"R and L/R\ 



******** 



* * * * 



* * 



* ft * 



± * 



i ■ * * 



Control procedure: 

• Repeatedly shift the switch key to the various 
positions - ON, OFF, LOCK and P. 

• Shift the tester selector to 0x1, 

• Connect the tester positive cable (+) to the termi- 
nal of cable R of the connector, and the negative 
cable (-) to cable terminal Br. 



8-5 



8-6 



SWITCH CHECK/ 
LIGHT INSPECTION 



j/^H* 1 








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"0" 


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ELEC 


^ 




BULB INSPECTION 



NOTE: 

Use the thin tester terminals to check continuity, as 
the terminals might come into contact with others 
inside the connector. 

• Check continuity between "R and Br* at switch 
positions ON (1), OFF (2), LOCK (3) and PARK 
(4). There must be continuity (ie the tester must 
show "0") at ON and there must be no continuity 
{ie the tester must show "«»■ ) at OFF, LOCK 
and PARK. Something is not working between 
M R and Br* if there is no continuity between these 
two points at position ON, or if there is some 
continuity in one of the other positions OFF, 
LOCK or PARK. 

NOTE: 

Check switch continuity various times. 



5. Continue to check continuity between T and 
UR* and *R and L/R" in the respective switch 
positions in the manner described above. 

6. If anything wrong is noted in any of the combi- 
nations, replace the switch component. 



LIGHT INSPECTION (HEADLIGHTS, TAIL 
LIGHT ANDBRAKE LIGHTS, DIRECTION 
INDICATOR LIGHT, INSTRUMENT 
LIGHTS, ETC) 

Check the continuity between the bulb terminals to 
see that they are undamaged. 

BULB TYPES 

The bulbs used are classified as shown to the left 
according to type of attachment. 

(A) and (B) are used mainly for headlights. 

(C) is used mainly for direction indicator lights and 
the rear and brake tights. 

(D) and (E) are used especially for instrument and 
other indication lights. 




BULB INSPECTION 

1 , Remove the bulb in question. 



NOTE: 

♦ Bulbs of type (A) and (B) use special supports 
{bulbhotders). Remove the bulbholder before 
removing the bulb. Most of these bulbholders 
may be removed by turning in an anticlockwise 
direction. 

♦ Most bulbs of type (C) and (D) may be removed 
from their housing by pushing them and turning 
them in an anticlockwise direction. 

♦ Bulbs of type (E) may be removed simply by 
pulling them out. 

CAUTION: 

When removing a bulb be careful to hold the 
bulbholder or its housing firmly- Never pull the 
cable, as it might detach from the terminal 
inside the connector. 



WARNING 



Keep inflammable products and hands well 
away from bulbs when they are on (danger of 
bums and fire). Do not touch the bulb before it 
is coo!. 

2. Check the continuity between the bulb 
terminals. 



Control procedure: 

• Set the tester selector to Q. x 1 . 

• Connect the tester terminals to the bulb pins. 
Take, lor example, a three pin bulb as shown in 
the figure. First check continuity between pins ( 1 ) 
and (2), connecting tester terminal (+) to pin (1) 
and terminal (-) to pole (2). Then check the 
continuity between poles (1) and (3), again con- 
necting tester terminal (+) to pole (1), and termi- 
nal (-) to pole (3). If the tester indicates <*>, even 
in one case only, the bulb must be replaced. 




3. Check the bulb attachment by installing a test 
bulb. Furthermore, during inspection of the 
bulbs, connect the tester terminals to the re- 
spective socket cables and check continuity 

as described. 



8-7 



8-8 



IGNITION SYSTEM 




IGNITION SYSTEM - CIRCUIT DIAGRAM 



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ft I 




IGNITION SYSTEM 



The diagram illustrates the ignition circuit inside the motorcycle electric system. 



ELEC 


^ 



For the colour code and complete legend, 


see 


page 


8-2. 




(1) CDIunit 








(19) 


Fuse 20A (main) 


(6) Main switch 








(22) 


1 Diode 


(9) ignition coil 








(23) 


Neutral switch 


(10) Sparkplug 








(24) 


2 Diode 


(1 2) Side stand switch 








(26) 


Engine stop emergency switch 


(1 3) AC generator (source coil/pick-up coil) 








(18) Battery 













9 26 




19 22 




23 12 



8-9 



8-10 



IGNITION SYSTEM 





DIAGNOSTICS 



IF THE IGNITION SYSTEM STOP WORKING 
(NO OR INTERMITTENT SPARK) 



Procedure 


Check: 


1. 


Fuse 20A (main) 


2. 


Battery 


3. 


Spark plug 


4. 


Amplitude of ignition spark 


5. 


Spark plug cap resistance 


6. 


ignition winding resistance 


7. 


Main switch 



8. Engine stop emergency switch 

9. Side stand switch 

10. Neutral switch 
11.2 Diode 

1 2. 1 Diode 

1 3. Pick-up coil resistance 

1 4. Wiring connections (whole connection system) 



NOTE: 



Before making the inspections mentioned, remove the following parts: 

1 . Side panel (left and right) 4, Fuel tank 

2. Seat 5. Air filter case 

3. Rear cowling 

To check functioning defects, use the following special tools, 




Dinamic spark tester: 

P/N. YM-34487 

P/N. 90890-03144 




Pocket tester: 
P/N.YU-03112 
P/N, 90890-03112 



1. Fuse 20A (main). 



Remove the fuse. 

Connect the pocket tester (£*x1) to the fuse. 
Check the continuity of the fuse. 
See section "INSPECTION AND REPLACE- 
MENT OF FUSE" in CHAPTER 3, 



DISCONTINUITY 



I 



Replace the fuse. 



o 



CONTINUITY 



2. Battery. 



Check the battery. 

Refer tothe section "BATTERY INSPECTION' 

in CHAPTER 3. 



Voltage: 
12.8V or more at 20°C (68°F) 



INCORRECT 




Clean the battery terminals. 

Recharge or replace the battery. 

Refer to the corresponding section in 

CHAPTER 3, 



o 



CORRECT 



IGNITION SYSTEM 




3. Spark plug- 



Check the conditions of the spark plug. 
Check the type of spark plug used. 
Check the electrodes gap. 
See the section on CHAPTER 3 on "SPARK 
PLUG INSPECTION." 



Standard spark plug: 

DPR8EA-9 (NGK), DPR9EA-9 (NGK) 




Electrodes gap: 
0*8 ~ 0.9 mm 



INCORRECT 




Correct the electrodes gap or replace the spark 
plug. 



o 



CORRECT 



4. Amplitude of the ignition spark. 



Detach the spark plug cap from the spark 
plug. 

Connect th e dynamic spark tester { 1 ) as shown 
in the figure. 

(2) Spark plug cap (3) Spark plug 
Turn the main switch to ON position. 




Check the amplitude of the ignition spark. 
Start the engine and increase the amplitude 
until the ignition becomes intermittent. 




Spark amplitude if the ignition 
system is efficient: 
6.0 mm 



IN COMPLIANCE WITH SPECIFICATIONS 



Minimum spark amplitude. 



4> 



THE IGNITION SYSTEM IS INEFFICIENT OR 
THERE IS NO SPARK 



8-11 



8-12 



IGNITION SYSTEM 




5. Spark plug cap resistance. 



Remove the spark pfug cap. 

Connect the pocket tester (£2x1 k) to the spark 

plug cap. 





Check that the spark plug cap has the specified 
resistance. 



S3 



A 



Resistance of spark plug cap: 
10kQat20°C{68°F) 



OUT OF SPECIFICATION 



The spark pfug cap is defective. 
Replace. 



o 



IN COMPLIANCE 

WITH SPECIFICATIONS 




IGNITION SYSTEM 




G 



6- Ignition winding resistance- 



Disconnect the ignition coii cables. 
Connect the pocket tester (£2x1 ) to the ignition 

coii. 



Tester terminal (-*-) -> Pole {-*-) 
Tester terminal (-) -> Pole (-) 




Check that the primary coil winding has the 
specified resistance. 



E3 



ft®2 



Primary winding resistance: 
3.4 - 4.6 Q at 20°C (68°F) 
(Terminal (*) - Terminal (-) 



Connect the pocket tester (£ix1) to the ignition 
coil. 



Tester terminal (+} -> Spark plug cable (1) 
Tester terminal (-) -» Pole (+) 




Check that the secondary coil winding has the 
specified resistance. 



E3 



a®fl 



Secondary winding resistance: 
10.4- 15.6 kil at 20°C(68°F) 
(Spark piug cable - Pole {+) 



OUT OF SPECIFICATION 




The ignition coil is defective. 

Replace- 



g 



BOTH RESISTANCE 
VALUES ARE CORRECT 



8-13 



8-14 



IGNITION SYSTEM 





A 





7, Main switch. 



Disconnect the main switch connector from 
the bundle of cables- 
Connect the pocket tester (Qx1) to the main 
switch cables. 
See section "SWITCH CHECK*. 




o 



CORRECT 



8. Engine stop emergency switch. 



Disconnect the switch cables Red/White (1) 

and Red/White (2) on handle bar (R) from the 

bundle of cables- 
Connect the pocket tester (£2x1 ) to the switch 
cables. 



Tester terminal {+) -» 
Red/White (1) cable 

Tester terminal (-) *■» 
Red/White (2) cable 




I^Oftv^W 




o 



CORRECT 



INCORRECT 



The main switch is defective. Replace. 



INCORRECT 




The engine stop emergency switch is defective. 
Replace the right handlebar switch. 



IGNITION SYSTEM 







9, Side stand switch. 



Disconnect the side stand switch connector 

(Biack/White and Black) from the bundle of 

cables. 

Connect the pocket tester (£1x1) to the side 

stand switch cables. 



Tester terminal (+) -» Black/White cable (1) 
Tester terminal (-) -» Black cable (2) 




UP 



DOWN 



B/W 



B 



o— o 








CORRECT 



10, Neutral switch. 



Disconnect the neutral switch cable (Sky blue) 
from the bundle of cables. 
Connect the pocket tester (£2x1) to the neutral 
switch cables. 



Tester terminal (•*-) -* Sky blue cable (1) 
Tester terminal (-) -» Earth on the frame 




^^^ 


Sb 




In gear 






Neutral 


o— o 




Q 



CORRECT 



INCORRECT 



The side stand switch is defective. Replace. 



INCORRECT 



The neutral switch is defective. Replace. 



8-15 



8-16 



IGNITION SYSTEM 




11.2 Diode- 



Disconnect the diode cables from the harness. 
Connect the pocket tester {Qx1 ) to the diode 
terminals- 




Check the continuity of the diode- 



Tester connection 
table 



Cable (+) 



1 



1 



Cabfe (-) 



Correct 







O 



Incorrect 



0X0 







X 



X X 











o 



0: Continuity X: Discontinuity 



o 



CORRECT 



12. 1 Diode. 



Disconnect thediodecablesfromthe harness. 
Connect the pocket tester {Q x 1 ) to the diode. 




Check the continuity of the diode. 



Tester connection 
tabfe 



Cabte (+) Cable (-) 



Correct 



O 



Incorrect 



O 







O 



O: Continuity X: Discontinuity 



£ 



CORRECT 



INCORRECT 



The diode is defective. Replace. 



INCORRECT 



I 



The diode is defective. Replace. 




IGNITION SYSTEM 








13. Pick-up coil resistance. 



Disconnect the generator connector (Blue/ 
Yellow and Green/White} from the CD! unit. 
Connect the pocket tester {£l x 1 00) to pick-up 
coif cables. 



Tester terminal (+) -» 

Blue/Yellow cable (1) 
Tester terminal (-) -* 
Green/White cable (2) 




L/Y GA« 



1 



L/Y G/W 



TET 





Check that the pick-up coil resistance is as 
specified. 



E3l 



6@* 



Pick-up coil resistance: 

1 84 - 276 H at 20°C (68°F) 
(Blue/Yellow - Green/White) 



o 



COMPLY WITH 
SPECIFICATIONS 



14. Wiring connections. 



. 



Check the connections of the entire ignition 
system. See the "ELECTRICAL CIRCUIT 

DIAGRAM" section. 



o 



CORRECT 



The GDI unit is defective. Replace. 



OUT OF SPECIFICATIONS 




The pick-up coil is defective. Replace. 



UNCERTAIN CONNECTIONS 




8-17 



8-18 



ELECTRICAL STARTING SYSTEM 



ELECTRICAL STARTING SYSTEM - CIRCUIT DIAGRAM 







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ELECTRICAL STARTING SYSTEM 




The diagram illustrates the electrical starting system circuit inside the motorcycle electric system. 



NOTE: 

For the colour code and complete legend, see page 8-2- 



(6) 


Main switch 


(?) 


Clutch switch 


(12) 


Side stand switch 


(18) 


Battery 


(19) 


Fuse 20A (main) 


(20) 


Starter relay 



(21) Starter motor 

(22) 1 Diode 

(23) Neutral switch 

(25) Starter switch 

(26) Engine stop emergency switch 




19 22 



20 18 




23 12 



8-19 



8-20 



ELECTRICAL STARTING SYSTEM 



ELEC £3 




STARTER CIRCUIT FUNCTIONING 

The starting circuit of this model consists of the 
starter, its relay switch and the 1 diode, if the engine 
stop emergency switch and main switch are both 

on f the starter can only work if: 



The transmission is in neutral (neutral switch on) 

or if 

the clutch (ever is completely up against the handle- 
bar (clutch switch on) and the side stand is raised 
(stand switch on). 

The 1 diode prevents the starterfrom starting when 
none of these conditions is met. in this case the 
starter feed is off. When one or both of these 
conditions are met, the motor engine may be started 
by pressing the start switch. 



ELECTRICAL STARTING SYSTEM 




DIAGNOSTICS 



THE STARTER FAILS TO WORK 



Procedure 


Check: 


1. 


Fuse 20A (main) 


2. 


Battery 


3. 


Starter 


4. 


Starter relay 


5. 


Main switch 


6. 


Engine stop emergency switch 


7. 


Side stand switch 


8. 


Neutral switch 



9. Clutch switch 

10- Starter switch 
11.1 Diode 

12. Harness connection control (entire starter 
system) 



NOTE: 



Before starting inspections, remove the following parts: 

1 . Side panels (left and right) 

2. Seat 

3. Rear cowling 

4. Fuel tank 

5. Air filter case 

To inspect any operating faults defects use the following special tools. 




Pocket tester: 
P/N. YU-03112 
P/N* 90890-03112 



1. Fuse20A (main). 



Remove fuse- 
Connect the pocket tester (£2x1) to the fuse. 
Check fuse continuity- 
See the "FUSE INSPECTION AND RE- 
PLACEMENT" section in CHAPTER 3. 



DISCONTINUITY 



I 



Replace the fuse. 



v 



CONTINUITY 



2. Battery. 



• Check the conditions of the battery. 
Consult the "BATTERY INSPECTION" sec- 
tion in CHAPTER 3. 



Voltage: 
12.8V or more at 20°C (68°F) 



INCORRECT 








CORRECT 



Clean the battery terminals. 

Recharge or replace battery. 

See the "BATTERY INSPECTION" section in 

CHAPTER 3. 



8-21 



8-22 



ELECTRICAL STARTING SYSTEM 





W 

£ 



3. Starter- 



Connect the positive terminal of the battery 
(1) and the starter cable (2) using a connec- 
tion cable (3) *. 




Check the functioning of the starter. 



o 



IT RUNS 



4. Starter relay- 






Disconnect the starter relay connector. 
Connect the battery and frame to the starter 
relay connector, using a connection cable (1) 
as shown. 



Battery terminal (+) (2) •* 
Red/Yellow terminal (3) 
Earth on frame -* Blue/White terminal (4) 




Check the functioning of the starter. 



v 



IT RUNS 



A WARNING 



The connection cable used must have a section 
equal or superior to that of the battery cable, 
which might otherwise get burnt. 
This inspection is liable to produce sparks and 
should therefore be performed well away from 
inflammable substances. 



IT FAILS TO RUN 




The starter is defective. Repair or replace- 



IT FAILS TO RUN 




The starter relay is defective. Repair. 



ELECTRICAL STARTING SYSTEM 



ELEC 


M 



* 

G 



5. Main switch. 



Disconnect the main switch connector from 
the harness. 

Connect the pocket tester (£2x1) to the main 
switch terminal- 
Check the switch component for continuity 
between "Red (1) and Brown (2)\ See the 
"SWITCH CHECK" section. 




$ 



CORRECT 



6. Engine stop emergency switch. 



Disconnect the right handlebar switch con- 
nector from the harness- 
Connect the pocket tester (£2x1) to the emer- 
gency engine stop switch terminal, 
Check the switch component for continuity 
between 'Red/White (1) and Red/ White (2)", 
See the "SWITCH CHECK" section. 





OFF 



RV^RVJ 



RUNJO-hO 




G 



CORRECT 



INCORRECT 




The main swiich is defective. Replace. 



INCORRECT 



I 



The engine stop emergency switch is defective. 
Replace the right handlebar switch. 



8-23 



8-24 



ELECTRICAL STARTING SYSTEM 








7. Side stand switch. 



Disconnect the side stand switch connector 
from the harness- 
Connect the pocket tester (Dx1) to the 
terminals of side stand switch. 
Check the switch component for continuity 
between "Black (1) and Black {2) H . 

See the "SWITCH CHECK" section. 




g 



CORRECT 



8. Neutral switch. 



Disconnect the neutral switch cable from the 

harness. 

Connect the pocket tester (Qx1 ) to the neutral 

switch terminal. 

Check the switch component for continuity 

between "Sky blue (1) and Earth on frame". 

See the "SWITCH CHECK" section. 




CORRECT 



INCORRECT 




The side stand switch is defective. Replace. 



INCORRECT 




The neutral switch is defective. Replace. 



ELECTRICAL STARTING SYSTEM 



ELEC 


^ 



^ 





9. Clutch switch. 



Disconnect the clutch switch connector from 

the harness. 

Connect the pocket tester (0x1 ) to the clutch 

switch terminal. 

Check the clutch switch for continuity between 

"Black (1) and Black/Yellow" (2). 

See the "SWITCH CHECK' section. 






B 


B/Y 




Release 








Holt* 


0--0 






J5L. 












CORRECT 



10. Start switch. 



Disconnect the switch connector from the 
harness- 
Connect the pocket tester (£>x1) to the han- 
dlebar switch terminal. 
Check the switch for continuity between "Blue/ 
White (1) and Black (2)\ See the "SWITCH 
CHECK" section. 




o 



CORRECT 



INCORRECT 




The clutch switch is defective. Replace. 



INCORRECT 




The start switch is defective. 
Replace the right handlebar switch. 



6-25 



8-26 



ELECTRICAL STARTING SYSTEM 








11. 1 Diode. 



Disconnect the diode cables from the harness. 
Connect the pocket tester (£1 x 1 ) to the diode. 




Check the continuity of the diode. 



Tester connection 
table 



Cable (+) 



Cable (-) 



1 



Correct 







Incorrect 



O 



O 



o 



Or Continuity X: Discontinuity 



G 



CORRECT 



12, Harness connection. 



Check the connections of the whole starter 
system. 

See "ELECTRICAL CIRCUIT DIAGRAM* sec- 
tion. 



INCORRECT 




The diode is defective. Replace. 



UNCERTAIN CONNECTIONS 




Correct. 




STARTER MOTOR 



(1) 


O-ring 


(2) 


Armature 


(3) 


O-ring 


(4) 


Stator 


(5) 


O-ring 


(6) 


Brushes 



ELECTRICAL STARTING SYSTEM 



ELEC 


^ 



A 


BRUSH WEAR LIMIT: 
5.0 mm (0.20 In) 


B 


COMMUTATOR WEAR LIMIT: 
27 mm (1 .06 in) 


C 


MICA UNDERCUT: 
0.7 mm (0.027 in) 


D 


ARMATURE COIL RESISTANCE: 
0Qat2O°C(68°F) 




1 10 Nm (1.0 m»kg,7,2fHb) 




10 Nm{1.0m*kg,7,2fMb) 



8-27 



8-28 



ELECTRICAL STARTING SYSTEM 



ELEC 


M 




ELECTRICAL STARTING SYSTEM 



ELEC B 





Removal 

1. Remove: 

• Starter motor 

Refer to the "ENGINE REMOVAL AND 
SETTING" section in CHAPTER 4. 




Disassembly 

1. Remove; 

• Circlrp (1) 

• Drive gear {2) 



2. Remove: 

• Screws ( 1 ) 

• Bracket (2) 

• Washers (3) 

• Bracket (4) 

• Spacers (5) 

• Armature (6) 

• O-ring (7) 

• Stator (8) 

• Brushes assembly and bracket (9) 



1 Uil or more 



on 




3. Measure; 
• The mica undercut (b). 
Out of specification -> Level the undercut to 
the correct value using a hacksaw. 




5 



Mica undercut (b); 
0.7 mm 



NOTE: 

The mica insulation of the commutator must have 
an undercut to ensure proper functioning of (he 

commutator. 



4. Inspect: 

• Armature coils (insulation/continuity) 
Defective -» Replace the motor. 

How to inspect the excitation coils; 

• Connect the pocket tester and check continuity 
(1) and insulation (2). 

• Check the armature resistance. 



S3 



A 



Armature coil resistance: 
Continuity check (1): 
a at 20°C (68°F) 
Insulation check (2): 

Over 1 H12 at 20X (68°F) 



If the resistance is incorrect, replace the starter 
motor. 




Inspection and repair 



1. 



2. 



Inspect: 

• Armature 

Dirty *± Clean with sandpaper no. 600. 
Measure: 

• Diameter of the armature 

Out of specification -» Replace the motor. 





Wear limit of armature (a): 
27 mm 



5. Measure: 
• Brush length 
Out of specification -> Replace. 




Brush length limit (a): 

5*0 mm 



6. Inspect: 

• Brush spring strength 
Worn-out -> Replace all springs at once. 




Brush spring strength: 

680 ~ 920g 



8-29 



8-30 



ELECTRICAL STARTING SYSTEM 







7. Inspect: 

• 8earings (1) 

• Oil seal (2) 

• O- rings 
Wear/Damage -» Replace. 

• Bush (3) 

Damage -> Replace the support. 



Assembly 

Reverse the disassembly procedure- 
Pay attention to the following points: 
1. Install: 

♦ Brush assembly bracket 

NOTE: 





ELECTRICAL STARTING SYSTEM 

Installation 

1, Install: 

• Starter motor 




NOTE: 

Slightly grease the O-ring (1). 



jbf : ' ' *-^ 




Bolt (starter motor): 
10Nm(1.0mkg) 



See the "ENGINE OVERHAUL -ENGINE INSTAL- 
LATION" section in CHAPTER 4. 



Align the jutting surface (1) on the brush housing 
with the Slot (2). 




2. Install: 

• Stator (1) 

• Cover (2) 



NOTE: 

Align the reference marks (3) on the stator with the 
corresponding reference marks on the cover (4). 




3. Install: 

• Screws (1 




Screw (stator): 
5 Nm (0.5 mkg) 



8-31 



8-32 



CHARGING SYSTEM 



ELEC 


^ 




CHARGING SYSTEM - CIRCUIT DIAGRAM 




©': ©.'CD. 



CHARGING SYSTEM 



The diagram shows the charging circuit inside the motorcycle electric system. 

NOTE: 

For the colour codes and complete legend, see page 8-2. 




(13) AC Generator 

(14) Rectifier/Regulator 

(18) Battery 

(19) Fuse 20A (main) 





8-33 



8-34 



CHARGING SYSTEM 



DIAGNOSTICS 



THE BATTERY CANNOT BE CHARGED 



Procedure 

Inspect: 

1. Fuse 20A (main) 

2. Battery 

3. Charging voltage 

NOTE: 



4. Stator winding resistance 

5. Harness connection 
(whole connection system) 



Before earring out inspections, remove the following parts: 

1) Seat 

2) Rear cowling 

To check for functioning defects, use the following special tools. 



ft^ Pocket tester; 

4/ P/N. YU-03112 

P/N. 90890-03112 



1. Fuse 20A (main). 



Remove the fuse- 
Connect the pocket tester (12 x 1 ) to the fuse. 
Check fuse continuity. 
See the "FUSE INSPECTION AND RE- 
PLACEMENT* section in CHAPTER 3. 



H CONTINUITY 



2. Battery, 



Check the conditions of the battery. 

See the 'BATTERY INSPECTION" section in 

CHAPTER 3. 



Voltage: 
1 2.8V or over at 20°C (68°F) 



J L CORRECT 

* 



DISCONTINUITY 



I 



Replace the fuse. 



INCORRECT 




ELEC 

l 









Clean the battery terminals. 

Recharge or replace the battery. 

See the "BATTERY INSPECTION" section in 

CHAPTER 3- 



CHARGING SYSTEM 




* 



3. Charging voltage. 



Connect the pocket tester (DC 20V) to the 
battery. 



Tester cable (+) -> Battery terminal {+) 
Tester cable (-) -» Battery terminal (-) 




Start the engine and rev to about 5,000 rpm. 
Check the charging voltage. 



KS 



a®* 



Charging voltage: 
14.0 Vat 5,000 rpm 



NOTE; 



Use a fully charged battery. 



IN COMPLIANCE WITH 
SPECIFICATIONS 




The charging system is correct. 



^ 



OUT OF SPECIFICATIONS 



4, Stator coils resistance. 



Disconnect the AC generator connector from 
the harness. 

Connect the pocket tester {il x 1 ) to the stator. 
Check stator coils resistance. 



Tester cable (+) -> White cable (1) 
Tester cable (-) -4 White cable {3) 



Tester cable (+) ~» White cable (2) 
Tester cable (-) -» White cable (3) 



8-35 



8-36 



CHARGING SYSTEM 







m 



6@o 



Stator coil resistance: 

0.20 ~ 0.30 il at 20°C (68°F) 



OUT OF SPECIFICATIONS 




o 



IN COMPLIANCE WITH 
SPECIFICATIONS 



Stator winding is defective. 
Replace. 



5. Connections, 



Check the connections of the entire charging 

system. 

Seethe'ELECTRlCAlCtRCUfTDIAGRAM". 



UNCERTAIN CONNECTIONS 




g 



OK 



The rectifier/regulator is defective, Replace. 



8-37 



LIGHT SYSTEM 



ELEC 


M 




LIGHT SYSTEM - CIRCUIT DIAGRAM 




LIGHT SYSTEM 



The diagram shows the light system circuit inside the electric system of the motorcycle. 

NOTE: ; „ 



ELEC 


^ 



For the colour codes and complete legend, see page 8-2. 



(6) Main switch 

(15) Rear tail/stop light 

(18) Battery 

(19) Fuse 20A (main) 

(29) Dipped/high beam light switch 



(30) Lights switch 

(37) High beam light 

(40) Instrument fight 

(41) Front parking light 

(42) Dipped/high beam light 
(45) Number plate light 





8-39 



8-40 



LIGHT SYSTEM 





DIAGNOSTICS 



DIPPED/HIGH BEAM LIGHT, HIGH BEAM WARNING LIGHT, 

REAR STOPATAIL LIGHT, NUMBER PLATE LIGHT, FRONT PARKING 

LIGHT AND/OR INSTRUMENT LIGHTS FAIL TO TURN ON 



Procedure 

Check: 

1. Bulb 

2. Fuse 20A (main) 

3. Battery 

4. Main switch 

5. Lights switch and dipped/high beam light 

6. Harness connections (full system of connections) 



NOTE: 



Before beginning inspections, remove the following parts; 

1. Seat 

2. Rear cowling 

3. Cowling 

To check for defects use the following special tools. 




Pocket tester: 
P/N. YU-03112 
P/N. 90890-03112 



1, Bulb and bulbholder. 



Check the continuity of the bulb and bul- 
bholder. 

See the "BULB INSPECTION" section. 



DISCONTINUITY 




o 



CONTINUITY 



The bulb and/or bufbholder are defective. 
Replace. 



2. Fuse 20A (main). 



Remove the fuse. 

Connect the pocket tester (£2x1) to the fuse 

Check fuse continuity. 

See the "FUSE INSPECTION AND 

REPLACEMENT" section in CHAPTER 3. 



DISCONTINUITY 




Replace the fuse, 



o 



CONTINUITY 



LIGHT SYSTEM 




Q 



3. Battery. 



Check the conditions of the battery. 

See the "BATTERY INSPECTION" section in 

CHAPTER 3. 



Voltage: 
12.8V or over at 20°C (68°F) 



Jl CORRECT 



4, Main switch. 



Disconnect the main switch connector from 

the harness. 

Connect the pocket tester (Qx1) to the main 

switch terminals. 

See the "SWITCH CHECK" section. 




o 



CORRECT 



5. Light switch and dipped/high beam 
commutator. 



Disconnect the left handlebar switch unit 

connector. 

Connect the pocket tester (Qxl) to the 

connector terminals. 

Check the switch component for continuity 

between "Brown (1 ) and Blue {2)\ "Brown (1 ) 

and Green (3)", "Brown (1) and Yellow (4)". 

See the "SWITCH CHECK" section. 



INCORRECT 



Clean the battery terminals. 

Recharge or replace the battery. 

See the "BATTERY INSPECTION" section in 

CHAPTER 3. 



INCORRECT 




The main switch is defective. Replace. 



8-41 



8-42 



LIGHT SYSTEM 











CORRECT 



6. Harness connections. 



Check the connections of the entire light 
system. 



o 



CORRECT 



Check the conditions of each circuit for [he entire 

light system. 

See the 'ELECTRIC CIRCUIT DIAGRAM". 



INCORRECT 



The lights switch and/or dipped/high beam 
commutator are defective. Replace the left 
handlebar switch. 



DEFECTIVE CONNECTIONS 



Repair. 



8-43 



SIGNALLING SYSTEM 



ELEC 


M 




SIGNALLING SYSTEM 



ELEC 


M 



SIGNALLING SYSTEM - CIRCUIT DIAGRAM 







**1J 



>'fT 





g? 6* 



^3 . » 



I-*.* I ": 






■ill 



*©c; 



O 



s- 



m 





.£3 
1 



8 



tf* 6* 







"■" ill 






ip:iSl 






-Mi 





.in ,i v 



"T 

u: tt IMS* ■'". 



o 

-"t* 
o 



I'ir.?: 

,■ ■ i .:!|'---i«ii 
" ill 







*■. i'.i »!!\ 




: liar., -i, 



' «*'...«: 



■rwiPl i"" «"i!'^ "i-:i: ! >- ,.■ " 



EPTlilHi 




'"ll!!--*:: 

'i|'!sss". ! s!"ii!'i S , : ss: 

'■■■ife 'NRi'.i'*i!i! 
■;il|j:i!i!!:?;::i 



;>iv !i" ■.;;;•:■ & 




iti'-llr;! I 






i-^5||">|«S 



©(3(36 



^.- != XJ 



....._.^0© f 




:; .,;■■ ■!': !:■ .■'■ :■;'.; ■ ■,■■ ^— * i !,■ 





.nj 



-IT I* 1 Is 



■!;ii!:; ■i'- : :;;' 



!!i * 



The diagram shows the signalling system circuit inside the electric system of the motorcycle. 

NOTE: 

For the colour codes and complete legend, see page 8-2. 



(6) Main switch 

(8) Front brake switch 

(1 1 } Rear brake switch 

(15) Rear tail/stop light 

(16) Right rear direction indicator light 

(17) Left rear direction indicator light 

(18) Battery 

(19) Fuse 20A (main) 
(23) Neutral switch 



(27) Horn switch 

(28) Turn direction indicator switch 

(32) Horn 

(33) Direction indicators intermittence 

(34) Left front direction indicator light 

(35) Right front direction indicator light 
(38) Neutral light m H" 

(43) Direction indicator light 





8-45 



8-46 



SIGNALLING SYSTEM 





DIAGNOSTICS 



THE FLASHER LtGHTS, BRAKE LIGHT AND/OR WARNING LIGHTS FAIL TO TURN ON 
THE HORN FAILS TO SOUND 



Procedure 

Check; 

1. Fuse 20A (main) 

2. Battery 

3. Main switch 

4. Harness connections 
(entire system of connections) 

NOTE: 



Before starting inspections, remove the following parts: 

1. Seat 

2. Rear cowling 

3. Cowling 

To check for operating faults use the following special tools. 



ft^ Pocket tester: 

V P/N.YU-03112 

P/N. 90890-03112 



1. Fuse 20A (main). 



Remove fuse. 

Connect the pocket tester (Qx1) to the fuse- 
Check fuse continuity. 
See the "FUSE INSPECTION AND RE- 
PLACEMENT" section in CHAPTER 3. 



DISCONTINUITY 




Replace the fuse. 



o 



CONTINUITY 



2. Battery. 



INCORRECT 



Check the conditions of the battery. 
Consult the "BATTERY INSPECTION" sec- 
tion in CHAPTER 3. 



Voltage: 

12.8V or more at 20°C <68°F) 




Clean the battery terminals. 
Recharge or replace battery. 

Consult the "BATTERY INSPECTION" sec- 
Hon in CHAPTER 3. 



Jl CORRECT 
* 



SIGNALLING SYSTEM 




V 

V 



3. Main switch 



Disconnect the main switch connector from 

the harness. 

Connect the pocket tester (Qx1) to the main 

switch terminals. 

See the "SWITCH CHECK" section. 




g 



CORRECT 



4. Harness connections. 



Check the connections of the entire signalling 

system. 

See the "ELECTRICAL CIRCUIT DIAGRAM 1 

section. 



o 



CORRECT 



Check the conditions of each signalling system 

circuit. 

See the "SIGNALLING SYSTEM CONTROL" 

section. 



DISCONTINUITY 



The main switch is defective. Replace. 



UNCERTAIN CONNECTIONS 




Repair. 



8-47 



8-48 



SIGNALLING SYSTEM 





SIGNALLING SYSTEM CONTROL 

1 . The horn does not work. 



1. Horn switch. 



Detach the left handlebar switch connectors 
from the harness- 
Connect the pocket tester (flxl ) to the switch 
terminals. 

Check the switch component for continuity 
between "Pink (1) and Black (2)* cables. 
See the "SWITCH CHECK" section. 




o 



CORRECT 



2. Voltage. 



Connect the pocket tester (DC 20V) to the 
horn. 



Tester terminal (+) «-» 

Brown terminal (1) 
Tester terminal (-) -» Earth on the frame 



®-= 




Turn the main switch to ON. 
Check the voltage (12V) on the "Brown" ter- 
minal of the horn. 



DISCONTINUITY 




The switch is defective. Replace the left handle- 
bar switch. 



OUT OF SPECIFICATIONS 



The circuit from the main switch to the horn 

terminal is defective. Repair. 



$ 



IN COMPLIANCE WITH 
SPECIFICATIONS (12V) 



SIGNALLING SYSTEM 




* 



3. Horn. 



Detach the "Pink" cable from horn terminal. 
Connect a special cable (1 ) to the horn cable 
and earth the cable. 
Turn the main switch to ON. 




* 



THE HORN DOES 
NOT WORK 



4. Voltage. 



Connect the pocket tester (DC 20V) to the 

"Pink* terminal of the horn. 



Tester terminal (+) -» Pink cable (1) 
Tester terminal (-) -> Earth on the frame 




Turn the main switch to ON. 

Check the voltage (12V) on the"Red* terminal 

of the horn. 



THE HORN WORKS 




The horn is efficient. 



OUT OF SPECIFICATION 



The horn is defective. Repair. 



o 



IN COMPLIANCE WITH 

SPECIFICATIONS (12V) 



Repair or replace the horn. 



8-49 



8-50 



SIGNALLING SYSTEM 




L-15 



2. The brake light fails to turn on. 



1, Bulb and bulbholder. 



Check the continuity of the bulb and 

bulbholder. 

See the "BULB INSPECTION 11 section. 



o 



CONTINUITY 



2, Brake switch. 



Disconnect the brake switch connectors from 

the harness. 

Connect the pocket tester (Qx1 ) to the brake 

switch terminals. 

Check the front brake switch component for 

continuity between "Green/Yellow (1) and 

Brown (2)" terminals, and the rear brake switch 

for continuity between the terminals (3) and 

(4). See "SWITCH CHECK" section. 




~~~ — ^^|C/Y 


0f 


ON (Pull in) O- 




OFFiFree] | 






JO- 





© h 




ON 
(Step down) 



OFf(Free) 



o-o 




[A] Front brake switch 

[B] Rear brake switch 



o 



CORRECT 



DISCONTINUITY 



Replace the bulb and/or bulbholder. 



INCORRECT 



The brake switch is defective. Replace. 



SIGNALLING SYSTEM 







3. Voltage, 



Connect the pocket tester (DC 20V) to the 
bulbholder connector. 



Tester terminal (+) -> 

Green/Yellow cable (1) 
Tester terminal (-) -> Black cable (2) 




Turn the main switch to ON. 

The brake lever is pulled or the brake pedal is 

pressed. 

Check the voltage (1 2V) on the "Green/Yellow" 

cable of the bulbholder connector. 



OUT OF SPECIFICATION 




The circuit from the main switch tothe bulbholder 
connector is defective. Repair. 



a 



IN COMPLIANCE WITH 

SPECIFICATIONS (12V) 



The circuit is efficient. 



3. The direction indicator light and/or the direc- 
tion indicator warning light fail to flash. 



1. Bulb and bulbholder. 



Check the continuity of the bulb and 

bulbholder. 

See the "BULB INSPECTION" section. 



DISCONTINUITY 




Replace the bulb and/or bulbholder. 



$ 



CONTINUITY 



2. Direction indicator lights switch. 



Disconnect the left handlebar switch connec- 
tor from the harness. 

Connect the pocket tester (£1x1) to the left 
handlebar switch cables. 



8-51 



8-52 



SIGNALLING SYSTEM 





Check the switch component for continuity 

between "BrownAVhite (1 ) and Chocolate (2)" 
and "Brown/White (1) and Dark Green (3) H . 
See the "SWITCH CHECK" section. 




o 



CORRECT 



3. Direction indicator intermittence. 



Connect the pocket tester {DC 20V) to the 
indicator intermittence. 



Tester terminal (+) -> 
Brown terminal {1) 
Tester terminal (-) -> Earth on frame 





Turn the main switch to ON. 

Check the voltage (1 2V) on the 'Brown" cable 

to the intermittence terminal. 



INCORRECT 




The direction indicator switch is defective. 
Replace. 



OUT OF SPECIFICATIONS 



The circuit from the main switch to the intermit- 
tence connector is defective. Repair, 



g 



IN COMPLIANCE WITH 
SPECIFICATIONS (12V) 



SIGNALLING SYSTEM 







4. Voltage. 



Connect the pocket tester (DC 20V) to the 
bulbholder connector. 



Tester terminal (+) -> 

Brown/White terminal (1) 
Tester terminal (-) -» Earth on frame 



<^a 





Turn the main switch to ON. 

Check the voltage (12V) on the "Blue" cable 

to the bulbholder connector. 



OUT OF SPECIFICATIONS 




The intermittence is defective. Repair. 



o 



IN COMPLIANCE WITH 
SPECIFICATIONS (12V) 



8-53 



8-54 



SIGNALLING SYSTEM 





W 





5. Voltage. 



Connect the pocket tester (DC 20V) to the 
bulbholder connector. 

Connect the left handlebar switch connector 
to the harness. 



To the left flasher light: 
Tester terminal (+) -> 

Chocolate terminal (1) 
Tester terminal (-) -» Earth on frame 



To the right flasher light: 
Tester terminal (+) -4 

Dark Green terminal (2) 
Tester terminal (-) -» Earth on frame 




DC20V 




Turn the main switch to ON. 

Turn the direction indicator switch to "L" or 

"FT. 

Check the voltage (it flashes, at 2-8V) on the 
"Chocolate" or "Dark green* cable at the 
bulbholder connector. 



o 



OUT OF SPECIFICATIONS 



The circuit from the direction indicator switch to 
the bulbholder is defective. Repair. 



IN COMPLIANCE WITH 
SPECIFICATIONS (12V) 



The circuit is efficient. 



SIGNALLING SYSTEM 




4. The neutral warning light "N* fails to turn on, 



1, Bulb and bulbholder. 



Check the continuity of the bulb and 

bulbholder. 

See the "BULB INSPECTION" section. 



^ 



CONTINUITY 



2, Neutral switch. 



Disconnect the neutral switch cable from the 

harness. 

Connect the pocket tester (Qx1 ) to the neutral 

switch terminals. 

Check the switch component for continuity 

between "Sky blue (1) and earth". 

See the "SWITCH CHECK" section. 




tn gear 



Neutral 



SU 



o--o 



Sb •£ 



i 




$ 



CORRECT 



3. Voltage- 



Connect the pocket tester {DC 20V) to the 
bulbholder connector. 



Tester terminal (+) -» 
Sky blue cable (1) 
Tester terminal (-) -» Earth on frame 



DC20V 




DISCONTINUITY 



Replace the bulb and/or bulbholder. 



INCORRECT 




The neutral switch is defective. Replace, 



8-55 



8-56 



SIGNALLING SYSTEM 






Turn the main switch to ON. 

Check the voitage (12V) on the "Sky blue" 

cable of the bulbholder connector. 



OUT OF SPECIFICATIONS 



I 



o 



IN COMPLIANCE WITH 
SPECIFICATIONS (12V) 



4. Neutral switch cable. 



Disconnect the neutral switch connector from 
the harness and the bulbholder connector. 
Connect the pocket tester (£2x1) to the neutraf 
switch cable (on the harness side) (1 ) and the 
bulbholder connector (2). 



® 



/ — s 


r^, 








Y/Gr 

5 


Y Oi 






W3 


D9 


n"®S 


Gffli 


^ 


B 






l i-x- 






f \T 













2ZZZZZZZ2ZZZZ 




The circuit from the main switch to the bulbholder 
connector is defective. Repair. 



DISCONTINUITY 



Thecircuitfrom the bulb connectorto the neutral 
switch cable is defective. Repair. 



o 



CONTINUITY 



The circuit is efficient. 



8-57 



COOLING SYSTEM 



ELEC 


M 



COOLING SYSTEM - CIRCUIT DIAGRAM 







-W^W- 




COOLING SYSTEM 



The diagram show the cooling system circuit inside the electric system of the motorcycle. 

NOTE: 

For the colour codes and complete legend, see page 8-2. 




(2) Fan motor 

(3) Fuse 7.5A (fan motor) 

(4) Thermo switch 

(5) Thermo unit 

(6) Main switch 



(18) Battery 

(19) Fuse 20A (main) 

(36) Engine temperature cooling liquid indicator 





8-59 



8-60 



COOLING SYSTEM 





DIAGNOSTICS 



THE FAN MOTOR FAILS TO RUN 



Procedure 

Check: 

1 . Puses {main and fan motor) 

2. Battery 

3. Main switch 

4. Fan motor (1st test) 

5. Fan motor (2nd test) 



6. Thermo switch 

7. Harness connections (entire system of 

connections) 



NOTE: 



Before making the inspections mentioned, remove the following parts: 

1. Seat 

2. Cowling 

To check for functioning defects, use the folfowing special tools. 



fi^s Pocket tester: 

V P/N. YU-03112 

P/N. 90890-03112 



1 . Fuses (main and fan motor) 



Remove the fuses. 

Connect the pocket tester (Q x 1 ) to the fuse. 

Check fuse continuity. 

See the "FUSE INSPECTION AND 

REPLACEMENT" section in CHAPTER 3. 



DISCONTINUITY 



1 



Replace the fuse (es). 



g 



CONTINUITY 



2. Battery. 



Check the conditions of the battery. 

See the "BATTERY INSPECTION' section in 

CHAPTER 3. 



Voltage: 
12.8V or over at 20°C (68°F) 



INCORRECT 



1 



Clean the battery terminals. 

Recharge or replace the battery. 

See the "BATTERY INSPECTION" section in 

CHAPTER 3. 



JT CORRECT 

* 



COOLING SYSTEM 




* 





3. Main switch. 



Disconnect the main switch connector from 

the harness. 

Connect the pocket tester (Qx1) to the main 

switch terminals. 

See the "SWITCH CHECK" section. 




o 



CORRECT 



4. Fan motor (1st Test). 



Disconnect the fan motor connector. 
Connect a battery (12V) as shown. 



Tester terminal (+) -» 
Blu/White cable (1) 
Tester terminal {-) -» Black cable (2) 




Check the functioning of the fan motor. 



INCORRECT 




The main switch is defective. Replace. 



IT FAILS TO RUN 




The fan motor is defective. Replace. 



8-61 



8-62 



COOLING SYSTEM 



ELEC £=| 




COOLING SYSTEM 




5. Fan motor {2nd Test) 



• Disconnect the Ihermo switch connector 
("Blue/White" and "Brown"). 

• Turn the main switch to ON. 

• Connect the connector terminals (harness 
side) using an auxiliary cable (1) as shown. 




<E 



Vifl Br t 



^^7, 




£ 



TURN 



6. Thermo switch. 


• Remove the thermo switch from the thermostat 
housing. 

• Connect the pocket tester (fl x 1) to the 
thermo switch (1). 

• Plunge the thermo switch into the coolant (2). 

• Check thermo switch continuity. 

• During the coolant heating take the 
temperatures by a thermometer (3). 


Test 
step 


Coolant 
temperature 


Correct 


1 


Less than 105±3°C 
(221.0 ±5.4°F) 


X 


2 


More than 105±3°C 
(221.0 ±5.4°F) 





3* 


From 105to98°C 
(From 221.0 to 208.4°F) 





4* 


Less than 98°C (208.4°F) 


X 


1st and 2nd steps: overheating test 
3rd and 4th steps: cooling test 
0: Continuity X: Discontinuity 



IT FAILS TO RUN 



The circuit from the main switch to the fan motor 
terminals is defective. Repair. 




BAD CONDITIONS 




The thermo switch is defective. Replace. 



a 



GOOD CONDITIONS 



7. Harness connections. 



Check the connections of the entire cooling 
system. See the "ELECTRICAL CIRCUIT 
DIAGRAM" section. 



UNCERTAIN CONNECTIONS 



g 



CORRECT 



Correct, 



The circuit is efficient. 



A WARNING 



Take care the thermo switch doesn't fall to the 
ground. In this case replace it. 




Thermo switch: 
28Nm(2.8mkg) 
Water resistant sealant 



8-63 



8-64 



COOLING SYSTEM 



WITH ENGINE HOT THE COOLANT 
TEMPERATURE GAUGE FAILS TO INDICATE 





Procedure 

Check: 

1. Fuse 20A (main) 

2. Battery 

3. Main switch 

4. Thermo unit 

NOTE: 



5. Voltage 

6. Harness connections (entire system of con- 
nections) 



Before making the inspections mentioned, remove the following parts: 

1. Seat 

2. Cowling 

To check for functioning defects, use the following special tools. 




Pocket tester: 
P/N. YU-03112 
P/N. 90890-031 12 



1, Fuse 20A (main). 



Remove the fuse. 

Connect the pocket tester (0x1) to the fuse. 

Check fuse continuity. 

See the "FUSE INSPECTION AND RE- 
PLACEMENT* section in CHAPTER 3. 



DISCONTINUITY 



I 



Replace the fuse. 



o 



CONTINUITY 



2. Battery. 



Check the conditions of the battery. 

See the "BATTERY INSPECTION" section in 

CHAPTER 3. 



Voltage: 
12.8V or over at 20°C (68°F) 



INCORRECT 



Clean the battery terminals. 

Recharge or replace the battery. 

Seethe # BATTERYINSPECT10N"sectionin 

CHAPTER 3, 



o 



CORRECT 



3. Main switch. 



Disconnect the main switch connector from 
the harness. 

Connect the pocket tester (Qx1) to the main 
switch terminals. 

See the 'SWITCH CHECK" section. 



COOLING SYSTEM 





& 



CORRECT 



4, Thermo unit- 



Remove the thermo unit. 



A WARNING 



Handle the thermocouple with great care. 
Avoid knocks and do not let it fall over. If it 
does fail, it must be replaced. 

• Plunge the thermo unit (1 } into the coolant (2). 

• Measure resistance at various temperatures, 
as shown rn the table. 

(3) Thermometer 





T 


© o 


v.. 


; I 



Coolant 
temperature 



50 n C(122°F) 



Resistance 



15412 



80°C{176°F) 



10O'C(212°F) 



120°C(248°F) 



47-53Q 



26-2912 



16a 



After checking the thermo unit, assemble it in 
its initial position. 



INCORRECT 



The main switch is defective. Replace. 



8-65 



8-66 



COOLING SYSTEM 




M-7 



elec m 




Thermo unit: 
15Nrn(1-5mkg) 
Water resistant sealant 



CAUTION: 



Never overtighten. 



OUT OF SPECIFICATIONS 




o 



IN COMPLIANCE WITH 
SPECIFICATIONS 



The thermo unit is defective- Replace. 



5. Voltage. 



Connect the pocket tester (DC 20V) to the 
connector terminals of the instruments. 



Tester terminate (+) -» 

Brown cable (1) 
Tester terminale (-) -» Black cable (2) 





Turn the main switch to ON. 

Check the voltage ( 1 2 V) on the "Brown* cable 

of the temperature gauge connector. 



OUT OF SPECIFICATIONS 




The circuit from the main switch to the tempera- 
ture gauge connector is defective. Repair. 



g 



IN COMPLIANCE WITH 
SPECIFICATIONS 



8. Harness connections. 



Check the connections of the entire cooling 
system. See the "ELECTRICAL CIRCUIT 
DIAGRAM" section. 



UNCERTAIN CONNECTIONS 



o 



CORRECT 




The circuit is efficient. 




8-67 




ELECTRICAL SYSTEM DIAGRAM 




ELECTRICAL SYSTEM DIAGRAM 



COLOUR CODE 

B - Black 

Br - Brown 
Ch - Chocolate 
Dg - Dark green 
G - Green 
L - Blue 
O - Orange 
P - Pink 
R -Red 
Sb - Sky blue 
W * White 
8/R -Black/Red 
BAV - Black/White 
Gy - Grey 
Y - Yellow 
L/W -Blue/White 
B/Y - Black/Yellow 
UR - Blue/Red 
G/Y -Greenr/eHow 
L7Y -Blue/Yellow 
R/Y -Red/Yellow 
R/W - Red/White 
Y/R -Yellow/Red 
G/R -Green/Red 
G/W - Green/White 
W/L -White/Blue 



ffl 


CD! unit 


(2) 


Fan motor 


(3) 


Fuse (fan motor) 


(4) 


Thermo switch 


m 


Thermo unit 


m 


Main switch 


(7) 


Clutch switch 


(8) 


Front brake switch 


(9) 


Ignition coil 


(10) 


Spark plug 




(11) Rear brake switch 


(21) Starter motor 


(31) 


(12) Side stand switch 


(22) 1 diode (starter circuit) 


(32) 


(13) AC generator 


(23) Neutra! switch 


(33) 


(14) Rectifier/Regulator 


(24) 2 diode (ignition circuit) 


(34) 


(15) Rear stop/tatMight 


(25) Starter switch 


(35) 


(16) Right rear direction indicator light 


(26) Engine stop emergency switch 


(36) 


(1 7} Left rear direction indicator light 


(27) Horn switch 


(37) 


(18) Battery 


(28) Direction indicator tights switch 


(38) 


(19) Fuse (main) 


(29) Drrvtng beam/dimmers tights switch 


(39) 


(20) Starter motor relay 


(30) Lights switch 


(40) 



Low fuel warning tight switch 

Horn 

Direction indicator lamp relay 

Left front direction indicator tights 

Right front direction indicator lights 

Engine temperature cooling liquid indicator 

High beam warning fight 

"N" neutral light 

Low fuel light 

Control light 



(41) Front parking light 

(42) Headlight (dipped/high beam) 

(43) Direction indicator warning light 

(44) Rev. counter 

(45) Number plate light 



TRBL 
SHTG 


9 

II 




CHAPTER 9° 
TROUBLESHOOTING 



TRBL 
SHTG 


9 



FAILURE TO START/DIFFICULTIES IN STARTING M-11 

FUEL SYSTEM M-11 

ELECTRICAL SYSTEM M-11 

POOR ENGINE COMPRESSION M-11 

POOR PERFORMANCE AT IDLE SPEED M-12 

UNSATISFACTORY PERFORMANCE AT MEDIUM-HIGH SPEED M-12 

DIFFICULTIES IN CHANGING GEAR M-12 

GEAR CHANGE IMPOSSIBLE M-12 

THE GEAR PEDAL FAILS TO MOVE M-12 

DISENGAGING GEARS M-12 

CLUTCH SLIDES OR FAILS TO RELEASE M-13 

CLUTCH SLIDES M-13 

CLUTCH FAILS TO RELEASE M-13 

OVERHEATING OF ENGINE M-13 

EXCESSIVE ENGINE COOLING M-13 

DEFECTIVE BRAKES M-14 

POOR BRAKING M-14 

OIL LEAKS OR MALFUNCTIONING OF FRONT FORK M-14 

OIL LEAKS M-14 

MALFUNCTIONING M-14 

UNSTABLE STEERING M-14 

DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS M-15 

POOR HEADLIGHT ILLUMINATION M-15 

FREQUENT BURNING OF BULB M-15 

THE DIRECTION INDICATORS FAIL TO TURN ON M-15 

THE DIRECTION INDICATORS FAIL TO TURN OFF M-15 

DELAYED TURNING ON OF INDICATORS M-15 

EXCESSIVE INDICATOR INTERMITTENCE FREQUENCY M-15 

THE HORN FAILS TO WORK M-15 



FAILURE TO START/ 
DIFFICULTIES IN STARTING 





FAILURE TO START/ 
DIFFICULTIES IN STARTING 



TROUBLESHOOTING 



ELECTRICAL SYSTEM 

— Spark plug — 



NOTE: , „ , „ — _™™___ 

The troubleshooting tables that follow do not identify every cause of trouble. They may however prove helpful 
as a guide to identify trouble. To inspect, adjust or replace parts, refer to the appropriate section in the 
manual. 



FAILURE TO START/DIFFICULTIES IN STARTING 



FUEL SYSTEM 

— Fuel tank 



Fuel tap 



n 



PROBABLE CAUSES 

• Empty 

• Fuel litter obstructed 

• Fuel tank air cap passage obstructed 

• Petrol contains water or impurities or is adu Iterated 

Hose obstructed 



Carburetor 









Air lifter 



Fuel pump 




ignition coil 



Ignition unit 



Fuel filter obstructed 



Petrol contains water or impurities or is adulterated 

Pilot jet obstructed 

Pilot passage obstructed 

Infiltrations of air 

Deformation of float 

Needle vaive worn or scratched 

Needle valve insufficiently sealed 

Fuel level set wrongly 

Pifot jet set wrongly 

Starter jet obstructed 

Malfunctioning of the starter piston 



Switches and conductors 



Starter 



POOR ENGINE COMPRESSION 

— Cylinder and cylinder head 



• Air filter element obstructed 



♦ Fuel pump defective 

• Suction hose obstructed 



Piston and piston rings 



Crankcase and valves* crankshaft 



TRBL 
SHTG 


m 



PROBABLE CAUSES 

• Electrodes gap not correct 

• Electrodes worn 

• Feed cable interrupted 

• Wrong thermal grading of spar1< plug 

• Defective spark plug cap 

• Primary or secondary winding interrupted 

• High voltage cable defective 

• Defective coil 

• Defective unit 

• Defective pick-up coil 

• Woodruff tongue broken 






Main switch defective 

Engine stop emergency switch defective 

Harness with cable interrupted 

Neutral switch defective 

Starter switch defective 

Side stand switch defective 

Clutch switch defective 



• Starter defective 

• Defective starter relay 

• 1 and/or 2 diodes interrupted 

• Starter clutch defective 



PROBABLE CAUSES 

• Spark plug tightened insufficiently 

• Cylinder head or cylinder insufficiently tightened 

• Cylinder head gasket broken 

• Cylinder gasket broken 

• Cylinder worn, damaged or seized 

• Piston rings wrongly assembled 

• Piston rings worn, yielded or broken 

• Piston rings stuck together 

• Piston seized or damaged 



Poor crankcase sealing 

Borders of drive shaft oil seal damaged 

Poor vaive sealing 

Valves and housing with insufficient contact 

Valves out of phase 

Valve spring broken 

Crankshaft seized 

Camshaft seized 



• 



9-1 



9-2 



POOR PERFORMANCE AT IDLE SPEED/ 
UNSATISFACTORY PERFORMANCE AT MEDIUM-HIGH SPEED 





DIFFICULTIES IN CHANGING GEAR 



TRBL 
SHTG 


9 

■ 



POOR PERFORMANCE AT IDLE SPEED 

— Carburetor 



PROBABLE CAUSES 

• The starter piston fails to return freely 

• Pilot jet obstructed or toose 

• Pilot air jet obstructed 

• Pilot air screw wrongly set 

• Idle speed wrongly set 
(throttle vatve locking screw) 

• Throttle cable free play wrongly set 

• Carburettor flooded 



DIFFICULTIES IN CHANGING GEAR 

GEAR CHANGE IMPOSSIBLE 

- Clutch 



Electrical system. 



Valves 



Defective battery 
Defective spark plug 
Defective ignition unit 
Pick-up coil defective 
Defective ignition coil 



Valve free play wrongly set 



Engine oil 



UNSATISFACTORY PERFORMANCE AT MEDIUM-HIGH SPEED 

See "FAILURE TO START/DIFFICULTIES IN STARTING". 

(FUEL SYSTEM, ELECTRICAL SYSTEM, COMPRESSION SYSTEM and Valve Clearance} 



THE GEAR PEDAL FAILS TO MOVE 

— Gear shaft 



Carburetor 






PROBABLE CAUSES 

• Petrol contains water or impurities or is adulterated 

• Infiltrations of air 

• Deformation of fioat 
Defective diaphragm 
Needle valve worn or scratched 
Needle valve housing insufficiently sealed 
Needle stop position incorrect 
Needle clip position incorrect 
Fuel level set wrongly 
Main jet obstructed or loose 
Main nozzle obstructed or foose 



Gear cam, gear fork 



Transmission 



DISENGAGING GEARS 

— Gear shaft — 



Air filter 



Air fitter element obstructed 



Fuel pump 



Fuel pump defective 



Gear fork 



Gear cam 



PROBABLE CAUSES 

• Clutch cable wrongly set (clutch fails release) 

• Wrong position of driving tever 

• irregular engagement of push iever and push 
rod 

• Pressure plate deformed 

• Clutch springs not preloaded uniformly 

• Reference marks not aligned 

• Push rod broken 

• Clutch gear assy nut loose or thrust rod de- 
formed 

• Primary driven gear bearing defective 

• Driven plates deformed 

• Driving plates deformed 

• Clutch cable damaged 

• Oil level over maximum 

• Excessive viscosity of engine oil 

• Degradation 

PROBABLE CAUSES 

• Gear shaft deformed 



Groove with impurities or foreign bodies 

Gear fork stuck 

Fork guide bar deformed 



Transmission gears stuck 

Gears stuck by impurities or foreign bodies 

Wrong transmission assembly 



PROBABLE CAUSES 

• Gear tever set wrongly 

• Drum stop lever fails to return freely 

• Gear forks worn 




Transmission 



Shaft cam with thrust free play 
Gear cam groove worn 

Gear clutches worn 



9-3 



9-4 



CLUTCH SLIDES OR FAILS TO RELEASE 





OVERHEATING OF ENGINE/ 
EXCESSIVE ENGINE COOLING 



CLUTCH SLIDES OR FAILS TO RELEASE 



CLUTCH SLIDES 



J — Clutch 



Engine oil 



CLUTCH FAILS TO RELEASE 

See "GEAR CHANGE IMPOSSIBLE* 



Clutch 



Engine oil 



OVERHEATING OF ENGINE 
— Ignition system 



PROBABLE CAUSES 

• Clutch cable wrongly set 

• Clutch springs loose 

• Clutch spring yielded 

• Friction pfates worn 

• Clutch plates worn 

• Clutch improperly assembled 



* Oil level below minimum 

* incorrect gradation {low viscosity) 

* Degradation 



PROBABLE CAUSES 

• Pressure plate deformed 

• Ciutch spring not prefoaded uniformly 

• Reference marks not. aligned 

• Clutch gear assy nut loose 

• Primary driven gear bearing defective 

• Drive plates deformed 

• Driven plates deformed 

• Push rod broken 



Fuel feed system 



Engine compression 



Engine oil 



Brake 



Cooling system 



• Oil level over maximum 

♦ Excessive viscosity of engine oil 

* Degradation 



TRBL 
SHTG 


■ 



PROBABLE CAUSES 

• Incorrect electrode gap of spark plug 

• Spa* piug thermal gradation wrong 

• Ignition unit defective 

• incorrect carburetor main jet 
(incorrect setting) 

• Incorrect fue! level 

• Air filter element obstructed 

• Excess of carbon deposits 

• Incorrect oiflevel 

• Incorrect oil viscosity 

• Incorrect oil gradation 

• Pads fail to return freely 
(remains blocked) 



Engine coolant temperature 
gauge defective 
Thermo unit defective 
Engine coolant low teve! 
Thermostat defective 
Thermo switch defective 
Dirty or damaged radiator 
Fan motor shaft seized 
Fan motor damaged 
Fan motor fuse broken 



EXCESSfVE ENGINE COOLING 



THE ENGINE FAILS TO REACH 
STANDARD OPERATING TEMPERATURE 

Cooling system 



PROBABLE CAUSES 

Engine coolant temperature gauge defective 
Thermo unit defective 
Thermostat defective 
Thermo switch defective 
Fan motor fails to stop 






9-5 



9-6 



DEFECTIVE BRAKES/ 
OIL LEAKS OR MALFUNCTIONING OF FRONT FORK 



TRBL 
SHTG 


9 

■ 




DEFECTIVE BRAKES 

POOR BRAKING 

Front and rear disk brake 



UNSTABLE STEERING 



PROBABLE CAUSES 

• Brake pads worn 

• Brake disk worn 

• Water in the brake fluid 

• Brake fluid leak 

• Brake fluid tank defective 

• Bleed cap not sealed to calipers 

• Fastening bolt loose 

• Brake hose cracked 

• Brake disk dirty or greasy 

• Brake pads dirty or greasy 

• Incorrect brake fluid level 



OIL LEAKS OR MALFUNCTIONING OF FRONT FORK 



OIL LEAKS 



MALFUNCTIONING 



PROBABLE CAUSES 

• Inner tube deformed, damaged or rusty 

• Outer tube damaged or cracked 

• Oil seal lip damaged 

• Oil seal assembled incorrectly 

• Oil level incorrect (excessive) 

• Shock-absorber rod stop bolt loose 

• O-ring on cap broken 

• Drain bolt loose 

• Drain bolt gasket damaged 

PROBABLE CAUSES 

• Inner tube deformed, damaged or rusty 

• Outer tube deformed or damaged 

• Fork spring damaged 

• Piston worn or damaged 

• Shock-absorber rod deformed or damaged 

• Incorrect oil viscosity 

• Incorrect oil level 

• Cartridge defective (overhaul) 



Handle bar 



Steering 



Front fork 



Tyres 



Wheels 



Frame 



UNSTABLE STEERING 



TRBL 
SHTG 


9 

■ 



PROBABLE CAUSES 

• Assembled crooked or incorrectly 



Handle bar crown assembled incorrectly 
Lower bracket crooked 
Lower steering column installed incorrectly 
{ring nuts not tightened correctly) 
Bearing or bearing tracks damaged 

Oil level not the same in both tubes 
Spring broken 
Front fork crooked 



Tyre pressure incorrect for type of load 
Tyre pressure incorrect 
Tyres worn non-uniformly 



♦ Wheels balanced incorrectly 

♦ Wheel deformed 

• Bearing loose 

* Wheel axle deformed or loose 

• Wheels excessively off-centre 



Deformed 

Head tube damaged 

Ball track installed incorrectly 



Rear swing arm 



-j — • Bushes or bearings consumed 
' — • Deformed or damaged 



Rear shock absorber 



Spring yielded 

Spring preload incorrect 

Oil leak 



Transmission chain 



Chain set incorrectly 



Cowling 



t — * Damaged or broken 
' — ♦ Assembled incorrectly 



9-7 



9-8 



DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS 
DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS 



TRBL 
SHTG 


9 

■ 




DEFECTIVE FUNCTIONING OF LIGHTS AND INDICATORS 



DELAYED TURNING ON OF INDICATORS 



POOR HEADLIGHT ILLUMINATION 



PROBABLE CAUSES 

• Incorrect bulb 

• Excessive absorption of electrical accessories 

• Difficulties in charging (charging coil broken and/ 
or rectifier/regulator defective) 

• Uncertain connections 

• Wrong negative earthing or defective contact 

• Insufficient contacts (main switch or light 
switch) 

• Bulb gone 



EXCESSIVE INDICATOR 
INTERMFTTENCE FREQUENCY 



TRBL 
SHTG 


9 



PROBABLE CAUSES 

• Indicator relay defective 

• Insufficient battery capacity 
(battery almost flat) 

• Incorrect bulb 

• Main or direction indicator switch defective 



PROBABLE CAUSES 

• Incorrect bulb 

♦ Indicator relay defective 



FREQUENT BURNING OF BULB 



PROBABLE CAUSES 

• Incorrect bulb 

• Defective battery 

• Rectifier/regulator defective 

• Wrong negative earthing 

• Main switch and/or light switch defective 

• Bulbs gone 



THE HORN FAILS TO WORK 



PROBABLE CAUSES 

• Defective battery 

• Main or horn switch defective 

• Horn wrongly set 

• Defective horn 

• Harness cut off 



DIRECTION INDICATORS FAIL TO TURN ON 



PROBABLE CAUSES 

• Wrong negative earthing 

• Battery fiat 

• Defective turn indicators switch 

• Indicator relay defective 

• Harness cut off 

• Coupler connection loose 

• Bulb burnt out 



DIRECTION INDICATORS FAIL TO TURN OFF 



PROBABLE CAUSES 

• Indicator relay defective 

• Insufficient battery capacity 
(battery almost flat) 

• Bulb (front or rear) burnt out 

• Direction indicator switch defective 



9-9 



9-10